Suzuki 250, LT-Z250, LT-Z250K5 2005, LT-Z250K9 2009 Service Manual

FOREWORD

This manual contains an introductory description on the SUZUKI LT-Z250 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 vehicle and its maintenance. Use this section as well as other sections as a guide for proper inspection and service.

This manual will help you know the vehicle 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 vehicle.

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

* This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI vehicles.

If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you.

ENGINE

CHASSIS

GROUP INDEX

GENERAL INFORMATION

PERIODIC MAINTENANCE

DRIVE TRAIN

FUEL SYSTEM

LUBRICATION SYSTEM

ELECTRICAL SYSTEM



Inexperienced mechanics or mechanics without the proper tools and equipment

877-999-5686 mechanic and may render the vehicle unsafe for the rider.

1

2

3

4

5

6

7

8

9

' COPYRIGHT SUZUKI MOTOR CORPORATION 2003

99500-42175-03E

03 ENGINE.book Page 105 Tuesday, February 28, 2006 3:03 PM

03 ENGINE.book Page 105 Tuesday, February 28, 2006 3:03 PM

SUPPLEMENTS

LT-Z250K5 ( 05-MODEL)

10

LT-Z250K6 ( 06-MODEL)

11

LT-Z250K7 ( 07-MODEL)

12

LT-Z250K8 ( 08-MODEL)

13

LT-Z250K9 ( 09-MODEL)

14

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 you find the item and page you need.

COMPONENT PARTS AND WORK TO BE DONE

Under the name of each system or unit there is an exploded view which provides work instructions and other service information (e.g.; tightening torque, lubricating points and locking agent points).

Example: Rear suspension

1

Rear shock absorber

2

Swingarm

3

Bearing

A

Rear shock absorber mounting nut (Upper)

B

Rear shock absorber mounting nut (Lower)

C

Swingarm pivot nut

D

Axle housing mounting nut (RH)

E

Axle housing bolt

F

Axle housing mounting nut (LH)

@

ITEM

A

B

C

D

EF

N•m kgf-m

78 7.8

60 6.0

lb-ft

55.0

43.5

85 8.5

61.5

60

65

6.0

6.5

43.5

877-999-5686

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 SYMBOL DEFINITION

Torque control required.

Data beside it indicates specified torque.

Apply THREAD LOCK SUPER 1303 .

99000-32030

Indicates service data.

Apply THREAD LOCK SUPER 1322 .

99000-32110 (Except USA)

Apply oil. Use engine oil unless otherwise specified.

Apply hypoid gear oil.

Apply THREAD LOCK 1342 .

99000-32050

Apply THREAD LOCK SUPER 1360 .

99000-32130

Apply molybdenum oil solution.

(mixture of engine oil and SUZUKl

MOLY PASTE in a ratio of 1 : 1)

Apply SUZUKI SUPER GREASE A .

99000-25030 (USA)

99000-25010 (Others)

Apply SUZUKI SILICONE GREASE.

99000-25100

Apply or use brake fluid.

Measure in voltage range.

Measure in resistance range.

W

Apply SUZUKI MOLY PASTE.

99000-25160

Measure in current range.

99000-25140

PartShark.com

Apply SUZUKI BOND 1207B

99104-31140 (USA)

Measure in diode test range.

877-999-5686

99000-31140 (Others)

Measure in continuity test range.

Apply SUZUKI BOND 1215 .

99000-31110 (Except USA)

Use special tool.

1216B

Apply SUZUKI BOND 1216B .

99000-31230

 

GENERAL INFORMATION

GENERAL INFORMATION 1-1

1

CONTENTS

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

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

SUZUKI LT-Z250K4 (2004-MODEL) .............................................................1- 4

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

FUEL AND OIL RECOMMENDATION ..........................................................1- 4

FUEL (FOR CANADA AND USA) ..........................................................1- 4

FUEL (FOR THE OTHER COUNTRIES) ................................................1- 4

ENGINE OIL (FOR USA) ........................................................................1- 5

ENGINE OIL (FOR THE OTHER COUNTRIES) ....................................1- 5

REAR DRIVE GEAR OIL .......................................................................1- 5

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

BREAK-lN PROCEDURES ...........................................................................1- 5

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

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

DIMENSIONS AND DRY MASS ............................................................1- 7

ENGINE ..................................................................................................1- 7

DRIVE TRAIN .........................................................................................1- 7

CHASSIS ................................................................................................1- 8

ELECTRICAL .........................................................................................1- 8

CAPACITIES ..........................................................................................1- 8

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

1-2 GENERAL INFORMATION

WARNING/CAUTION/NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words.

!

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

"

Indicates a potential hazard that could result in vehicle damage.

NOTE:

Indicates special information to make maintenance easier or instructions clearer.

Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the vehicle. In addition to the WARNINGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a particular service operation, ask a more experienced mechanic for advice.

GENERAL PRECAUTIONS

!

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

* When two 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 handling toxic or flammable materials, make sure that the area you work in is well ven-

PartShark.com until they have cooled.

related to the system for leaks.

877-999-5686

GENERAL INFORMATION 1-3

"

* 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.

Always tighten the bolts and nuts diagonally from the inside toward outside and to the specified 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, all other fluids, batteries and tires.

* To protect the earth s natural resources, properly dispose of used vehicles and parts.

877-999-5686

1-4 GENERAL INFORMATION

SUZUKI LT-Z250K4 (2004-MODEL)

RIGHT SIDE

* Difference between photographs and actual vehicles depends on the markets.

LEFT SIDE

SERIAL NUMBER LOCATION

The frame serial number or V.I.N. (Vehicle Identification Number)

1

is stamped on the left side of the rear frame pipe. 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

by the Research Method.

877-999-5686

SUZUKI recommends that customers use alcohol-free unleaded gasoline whenever possible.

Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted.

Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than 10% ethanol. Gasoline/alcohol fuel may contain up to 5% methanol if appropriate cosolvents and corrosion inhibitors are present in it.

If the performance of the vehicle is unsatisfactory while using blended gasoline/alcohol fuel, you should switch to alcohol-free unleaded gasoline.

Failure to follow these guidelines could possibly void applicable warranty coverage. Check with your fuel supplier to make sure that the fuel you intend to use meets the requirements listed above.

FUEL (FOR THE OTHER COUNTRIES)

Use unleaded gasoline that is graded 91 octane or higher by the Research Method.

GENERAL INFORMATION 1-5

ENGINE OIL (FOR USA)

SUZUKI recommends the use of SUZUKI PERFORMANCE 4

MOTOR OIL or oils that meet API service classifications SF or

SG and that have a viscosity rating of SAE 10W-40. If engine oil with a rating of SAE 10W-40 is not available, select an alternative according to the chart.

ENGINE OIL (FOR THE OTHER COUNTRIES)

Use a premium quality 4-stroke motor oil to ensure longer service life of the vehicles. Use only oils that meet API service classifications SF or SG and that have a viscosity rating of SAE

10W-40. If engine oil with a rating of SAE 10W-40 is not available, select an alternative according to the chart.

REAR DRIVE GEAR OIL

Use hypoid gear oil that meets the API service classification GL-5 and is rated SAE #90. Use a hypoid gear oil with a rating of SAE #80 if the vehicle is operated where the ambient temperature is below 0 C (32 F).

BRAKE FLUID

#

Specification and classification: DOT 4

!

This vehicle uses a glycol-based brake fluid. Do not use or mix different types of brake fluid such as silicone-based and petroleum-based fluids for refilling the system, otherwise serious damage will result to the brake system.

Never use any brake fluid taken from old, used or unsealed containers.

Never reuse brake fluid left over from the last servicing or which has been stored for a long period of time.

BREAK-lN PROCEDURES

877-999-5686

exercised during its early life. Refer to the following break-in engine speed recommendations:

Keep to these break-in engine speed limits.

Break-in engine speeds

Initial 10 hours: Less than ‰ throttle

After the engine has been operated for 10 hours the engine to full throttle operation, for short periods of time.

1-6 GENERAL INFORMATION

INFORMATION LABELS

No.

LABEL or PLATE NAME

1

Certification plate

E

2

Information label

E

3

Gearshift pattern label

E

4

Gearshift pattern label

E

/

F

5

Tire air pressure label

E

6

Tire air pressure label and warning no-passenger label

F

7

General warning label

E

8

General warning label

F

9

Warning no-passenger label

E

0

Age, 16 Iabel

E

A

Age, 16 Iabel

F

B

Manual notice label

E

C

Gearshift label

E

D

Gearshift label

F

E

ICES Canada label

E

/

F

F

Compliance label

E

G

EC approval mark

* E-28: Fuel caution label enclosed.

E

: English

F

: French

A: Attached

E-19

APPLIED SPECIFICATION

E-28 E-33

A A

A

A

A

A

A

A A

A

A

A

A

A

A

A

A

A

A

A

A A

A

A

A

A

A

A

Front of left side frame

GENERAL INFORMATION 1-7

SPECIFICATIONS

DIMENSIONS AND DRY MASS

Overall length ...................................................... 1 720 mm (67.7 in)

Overall width ....................................................... 1 070 mm (42.1 in)

Overall height ...................................................... 1 090 mm (42.9 in)

Wheelbase .......................................................... 1 135 mm (44.7 in)

Front track ........................................................... 830 mm (32.7 in)

Rear track............................................................ 810 mm (31.9 in)

Ground clearance................................................ 230 mm ( 9.1 in)

Seat height .......................................................... 810 mm (31.9 in)

Dry mass ............................................................. 166 kg (365 lbs)

ENGINE

Type .................................................................... Four-stroke, air-cooled, OHC

Number of cylinders ............................................ 1

Bore..................................................................... 66.0 mm (2.598 in)

Stroke .................................................................. 72.0 mm (2.835 in)

Displacement ...................................................... 246 cm‡ (15.0 cu. in)

Compression ratio ............................................... 9.2 : 1

Carburetor ........................................................... MIKUNI BSR29, single

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

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

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

Idle speed............................................................ 1 500 – 100 r/min

DRIVE TRAIN

Clutch .................................................................. Wet multi-plate, automatic, centrifugal type

Transmission ....................................................... 5-forward and 1-reverse

Gearshift pattern, forward ................................... All up, foot lever operated

reverse ................................... Foot/hand operated

PartShark.com

3rd ................................................... 1.388 (25/18)

4th ................................................... 1.095 (23/21)

5th ................................................... 0.913 (21/23)

Reverse........................................... 2.833 (34/12)

Final reduction ratio............................................. 3.200 (32/10)

1-8 GENERAL INFORMATION

CHASSIS

Front suspension ................................................. Independent, double wishbone, coil spring, oil damped

Rear suspension .................................................. Swingarm type, coil spring, oil damped

Front wheel travel ................................................ 160 mm (6.3 in)

Rear wheel travel ................................................. 170 mm (6.7 in)

Caster .................................................................. 7 40 ......... 1G

Trail ...................................................................... 33 mm (1.30 in) ........ 1G

Toe-in................................................................... 5 mm (0.20 in) ..........1G

Steering angle...................................................... 45

Turning radius ...................................................... 2.7 m (8.9 ft)

Front brake........................................................... Disc brake, twin

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

Front tire size ....................................................... AT22 7-10

✩✩

, tubeless

Rear tire size ........................................................ AT20 10-9

✩

, tubeless

ELECTRICAL

lgnition type.......................................................... Electronic ignition (CDl) lgnition timing ....................................................... 5 B.T.D.C. at 1 500 rpm

Spark plug............................................................ NGK DR7EA or DENSO X22ESR-U

Battery.................................................................. 12 V 28.8 kC (8 Ah)/10 HR

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

Main fuse ............................................................. 20/15 A

Headlight.............................................................. 12 V 40/40 W

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

Neutral indicator light ........................................... 12 V 3 W

Reverse indicator light ......................................... 12 V 3 W

CAPACITIES

Fuel tank, including reserve ............................... 10.6 L (2.8/2.3 US/Imp gal)

NOTE:

reserve .............................................. 2.6 L (0.7/0.6 US/Imp gal)

Engine oil, oil change .......................................... 2 200 ml (2.3/1.9 US/Imp qt)

PartShark.com

* These specifications are subject to change without notice.

COUNTRY AND AREA CODES

The following codes stand for the applicable countries and areas:

CODE

E-19

E-28

E-33

COUNTRY OR AREA

EU

Canada

USA and California

GENERAL INFORMATION 1-9

 

PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-1

CONTENTS

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

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

MAINTENANCE AND TUNE-UP PROCEDURES ..........................................2- 3

AIR CLEANER .......................................................................................2- 3

EXHAUST PIPE NUTS AND MUFFLER BOLTS ...................................2- 5

VALVE CLEARANCE ............................................................................2- 5

SPARK PLUG ........................................................................................2- 7

FUEL LINE .............................................................................................2- 8

THROTTLE CABLE PLAY .....................................................................2- 9

ENGINE IDLE SPEED ............................................................................2- 9

ENGINE OIL AND OIL FILTER ..............................................................2-10

FINAL GEAR OIL ...................................................................................2-11

SPARK ARRESTER ...............................................................................2-12

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

BRAKES .................................................................................................2-14

BRAKE FLUID ........................................................................................2-15

BRAKE HOSE ........................................................................................2-17

TIRES .....................................................................................................2-17

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

SUSPENSIONS ......................................................................................2-19

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

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

COMPRESSION PRESSURE CHECK ............................................................2-24

COMPRESSION TEST PROCEDURE ...................................................2-24

PartShark.com

INITIAL ENGAGEMENT INSPECTION ..................................................2-26

2

6

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 vehicle operating at peak performance and economy.

NOTE:

More frequent servicing may be performed on vehicles that are use under severe conditions.

PERIODIC MAINTENANCE CHART

Item

Air cleaner

Exhaust pipe nuts and muffler bolts

Valve clearance

Interval Initial

1 month

T

I

Spark plug

Spark arrester

Engine idle speed

Throttle cable play

Fuel line

Engine oil and oil filter

Final gear oil

Clutch

Brakes

Brake fluid

I

I

R

I

Every

3 months

C

T

I

Replace every 18 months.

I

I

I

Replace every 4 years.

Replace every 2 years.

I

I

Replace every 2 years.

Brake hose

Tires

Suspensions

Steering

Chassis bolts and nuts

General lubrications

877-999-5686

I = Inspect and adjust, clean, lubricate or replace as necessary

I

T

L

T

I

I

L

R = Replace

T = Tighten

C = Clean

L = Lubricate

I

I

R

I

I

I

C

I

I

I

I

Every

6 months

C

T

I

I

MAINTENANCE AND TUNE-UP PROCEDURES

This section describes the servicing procedures for each item mentioned in the Periodic Maintenance chart.

AIR CLEANER

Clean every 3 months.

If the air cleaner is clogged with dust, intake resistance will be increased, with a resultant decrease in power output and an increase in fuel consumption. Check and clean the air cleaner element in the following manner:

Remove the seat. (

!

7-5)

Disconnect the air vent hose

1

.

Remove the air cleaner case cover

2

.

NOTE:

Be careful not to drop the O-ring into the air cleaner box that is attached to the air cleaner case cover.

Remove the air cleaner element

3

.

PERIODIC MAINTENANCE 2-3

Separate the polyurethane foam element

5

4

, element frame

877-999-5686

2-4 PERIODIC MAINTENANCE

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

Press the air cleaner element between the palms of both hands to remove the excess solvent: do not twist or wring the element, or it will tear.

Immerse the element in motor oil, and then squeeze out the excess oil leaving the element slightly wet.

A

Non-flammable cleaning solvent

B

Motor oil SAE #30 or SAE 10W-40

"

* 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 operate the engine without the element or with torn element. Make sure that the air cleaner element is in good condition at all times. Life of the engine depends largely on this component!

Remove the drain cap

7

of the air cleaner box to allow any water to drain out.

EXHAUST PIPE NUTS AND MUFFLER

BOLTS

Tighten initially at 1 month and every 3 months thereafter.

Tighten the exhaust pipe nuts

1

and muffler mounting bolts/ nuts

2

.

Remove the right footrest mud guard. (

!

7-7)

Tighten the muffler connecting bolt

3

.

#

Exhaust pipe nut: 23 N•m (2.3 kgf-m, 16.5 lb-ft)

Muffler connecting bolt: 23 N•m (2.3 kgf-m, 16.5 lb-ft)

Muffler mounting bolt/nut: 23 N•m (2.3 kgf-m, 16.5 lb-ft)

PERIODIC MAINTENANCE 2-5

VALVE CLEARANCE

Inspect initially at 1 month and every 3 months thereafter.

Excessive valve clearance results in valve noise and insufficient

Check the intake and exhaust valve clearances at the distances if necessary.

PartShark.com

Remove the fuel tank. (

!

Remove the spark plug. (

!

2-7)

$

09930-10121: Spark plug wrench set

Remove the valve timing inspection plug

1

and generator cover cap

2

.

2-6 PERIODIC MAINTENANCE

Remove the valve inspection caps

3

.

NOTE:

Valve clearance is to be checked when the engine is cold.

The intake and exhaust valves must be checked and adjusted when the piston is at Top-Dead-Center (TDC) on the compression stroke.

Turn the crankshaft until the TDC line

4

on the generator rotor aligns with the index mark

5

on the crankcase.

Insert the thickness gauge between the valve stem end and adjusting screw on the rocker arm to check the clearance.

If the clearance is out of specification, bring it into the specified range.

%

Valve clearance (when cold)

IN: 0.03 0 .08 mm (0.001 0. 003 in)

EX: 0.08 0 .13 mm (0.003 0. 005 in)

$

09900-20803: Thickness gauge or

09900-20804: Thickness gauge

"

ment.

PartShark.com

#

Valve clearance adjuster locknut:

Install the spark plug, valve timing inspection plug and generator cover cap to the specified torque of each.

#

Spark plug: 18 N•m (1.8 kgf-m, 13.0 lb-ft)

Valve timing inspection plug:

23 N•m (2.3 kgf-m, 16.5 lb-ft)

Generator cover cap: 15 N•m (1.5 kgf-m, 11.0 lb-ft)

PERIODIC MAINTENANCE 2-7

Apply grease to new O-rings and install them to the valve inspection caps.

&

09900-25030: SUZUKI SUPER GREASE A ( USA)

09900-25010: SUZUKI SUPER GREASE A ( Others)

Tighten the valve inspection caps.

SPARK PLUG

Inspect every 6 months.

Replace every 18 months.

SPARK PLUG REMOVAL

Disconnect the spark plug cap

1

and remove the spark plug.

$

09930-10121: Spark plug wrench set

HEAT RANGE

Check the spark plug heat range by observing the electrode s color. If the electrode of the spark plug is appearing wet or dark color, replace the spark plug with a hotter type one. If it is white or appearing glazed, replace the spark plug with a colder type one.

Standard

PartShark.com

Colder type DR8EA X24ESR-U

CARBON DEPOSITS

DR7EA

DENSO

877-999-5686

Check to see if there are carbon deposits on the spark plug. If carbon is deposited, remove it using a spark plug cleaner machine or carefully use a tool with a pointed end.

2-8 PERIODIC MAINTENANCE

SPARK PLUG GAP

Measure the spark plug gap using the thickness gauge. If the spark plug gap is out of specification, adjust the gap.

%

Standard

Spark plug gap: 0.6 0.7 mm (0.024 0.028 in)

$

09900-20803: Thickness gauge or

09900-20804: Thickness gauge

0.6 0.7 mm

(0.024 0.028 in)

ELECTRODE

Check the condition of the electrode.

If the electrode is extremely worn or burnt, replace the spark plug with a new one.

Also, replace the spark plug if it has a broken insulator, damaged threads, etc.

"

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

SPARK PLUG INSTALLATION

"

To avoid damaging the cylinder head threads; first, finger tighten the spark plug, and then tighten it to the specified torque using the spark plug wrench.

#

Spark plug: 18 N•m (1.8 kgf-m, 13.0 lb-ft)

FUEL LINE

PartShark.com

Inspect every 3 months.

Replace every 4 years.

877-999-5686

Inspect the fuel hose for damage and fuel leakage. If any damages are found, replace the fuel hose with a new one.

THROTTLE CABLE PLAY

Inspect initially at 1 month and every 3 months thereafter.

Adjust the throttle cable play

A

as follows:

Loosen the locknut

1

of the throttle cable.

Turn the adjuster

2

in or out to obtain the correct play.

%

Throttle cable play

A

: 3 5 mm (0.12 0.20 in)

After adjusting the throttle cable play, tighten the locknut

1

.

ENGINE IDLE SPEED

Inspect initially at 1 month and every 3 months thereafter.

NOTE:

Make this adjustment when the engine is fully warm.

Connect the electric tachometer or the multi circuit tester to the high-tension cord.

PERIODIC MAINTENANCE 2-9

and 1 600 r/min by turning the throttle stop screw knob

1

.

%

Engine idle speed: 1 500 – 100 r/min

$

09900-25008: Multi circuit tester set or

09900-26006: Tachometer

2-10 PERIODIC MAINTENANCE

ENGINE OIL AND OIL FILTER

Replace initially at 1 month and every 6 months thereafter.

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

ENGINE OIL REPLACEMENT

Place an oil pan under the engine oil drain plug

1

, and then drain out the engine oil by removing the engine oil drain plug

1

and engine oil filler cap

2

.

Tighten the engine oil drain plug

1

to the specified torque, and then pour new engine oil through the oil filler hole. When performing an oil change (without oil filter replacement), the engine will hold about 2.2 L (2.3 US qt, 1.9 lmp qt) of oil. Use the engine oil that meets the API service classifications SF or

SG and that has the viscosity rating of SAE 10W-40.

#

Engine oil drain plug: 21 N•m (2.1 kgf-m, 15.0 lb-ft)

Install the oil filler cap

2

.

Start the engine and allow the engine to run for a few minutes at idling speed.

Turn off the engine and wait about three minutes, and then check the oil level on the dipstick

3

. If the level is below upper line, add oil to that level. The vehicle must be in a level

877-999-5686

OIL FILTER REPLACEMENT

Drain engine oil. (

!

Above)

Remove the oil filter cap

1

.

Remove the oil filter and O-rings.

PERIODIC MAINTENANCE 2-11

Apply engine oil lightly to new O-rings

A

and

B

before installing the oil filter cap.

Install the new O-ring

A

onto the oil filter fitting boss of the clutch cover.

Install the new O-ring

B

to the groove of the oil filter cap.

Install new oil filter

2

.

Install the spring

3

and oil filter cap

4

.

Pour new engine oil through the oil filler. When performing the oil filter change, the engine will hold about 2.3 L (2.4 US qt,

2.0 Imp qt) of oil.

After three minutes of engine idling, check the oil level.

(

!

2-10)

%

Engine oil capacity

Oil change: 2.2 L (2.3 US qt, 1.9 lmp qt)

Oil and filter change: 2.3 L (2.4 US qt, 2.0 lmp qt)

Engine overhaul: 2.5 L (2.6 US qt, 2.2 lmp qt)

"

When reassembling the oil filter, make sure that the oil filter is installed as shown above. If the filter is installed improperly, serious engine damage may result.

FINAL GEAR OIL

Inspect every 6 months.

Replace every 2 years.

To change the final gear oil, locate the vehicle on a level position and carry out the following steps. Use SAE #90 hypoid gear oil which is rated GL-5 under the API classification system. Use where the ambient temperature is below 0 C or 32 F.

bolts.

PartShark.com

Remove the final gear case under cover

1

by removing three

2-12 PERIODIC MAINTENANCE

Place an oil pan under the final gear case, and then drain oil by removing the drain plug

2

and filler plug

3

.

Tighten the drain plug

2

.

Remove the oil level check plug

4

and pour the specified oil through the filler hole until the oil over flows from the oil level check hole.

Tighten the filler plug

3

and the oil level check plug

4

.

%

Final gear oil capacity:

190 ml (6.42 US oz, 6.69 lmp oz)

#

Final gear oil drain plug: 26 N•m (2.6 kgf-m, 19.0 lb-ft)

Final gear oil filler plug: 26 N•m (2.6 kgf-m, 19.0 lb-ft)

SPARK ARRESTER

Clean every 6 months.

Remove the spark arrester bolt

1

.

Extract the spark arrester

2

from the muffler.

Clean the spark arrester

2

with a brush.

'

#

Only clean the spark arrester in an open area away from combustible materials. Exhausted hot carbon

877-999-5686

CLUTCH

Adjust every 6 months.

Remove the clutch adjuster cap

1

.

NOTE:

Adjust the clutch release, when the engine is cold.

Loosen the locknut

2

.

Tighten the adjusting screw

3

until it stops.

Loosen the adjusting screw

3

1/16 1 /8 turn.

Tighten the locknut

2

to the specified torque while holding the adjusting screw

3

.

#

Locknut

2

: 23 N•m (2.3 kgf-m, 16.5 lb-ft)

Apply engine oil to the O-ring and cap thread lightly.

Tighten the clutch adjuster cap to the specified torque.

#

Clutch adjuster cap: 15 N•m (1.5 kgf-m, 11.0 lb-ft)

PERIODIC MAINTENANCE 2-13

2-14 PERIODIC MAINTENANCE

BRAKES

Inspect initially at 1 month and every 3 months thereafter.

BRAKE PADS

Remove the front wheels. (

!

7-11)

The extent of brake pad wear can be checked by observing the limit line

1

on the side of brake pads. When the wear reaches the limit line, replace the pads with new ones. (

!

7-19)

"

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

BRAKE SHOES

This vehicle is equipped with the brake lining indicator on the rear brake.

To check the wear of the rear brake lining, perform the following steps:

Make sure that the rear brake system is properly adjusted.

With fully applying the rear brake, check if the indicator plate

1

is within the range

2

embossed on the brake panel.

If the indicator plate

1

is out of the range

2

, the brake shoe assembly should be replaced with new ones. (

!

7-46)

REAR BRAKE PEDAL AND LEVER

The procedure for adjusting the rear brake pedal and brake lever is as follows:

NOTE:

First adjust the brake pedal and next adjust the brake lever.

Brake pedal (Major brake adjustment)

Check that the brake pedal play

%

Brake pedal play

PartShark.com

A

: 20 30 mm (0.8 1 .2 in)

Turn the adjuster

1

until the play

A

reaches 20 30 m m (0.8

1 .2 in).

PERIODIC MAINTENANCE 2-15

Rear brake lever (Minor brake adjustment)

After adjusting the brake pedal, check the rear brake lever play. The brake lever play

B

as measured at the lever holder should be between 3 5 mm (0.1 0.2 in) when the lever is lightly pulled in towards the grip. If adjustment is necessary, slacken the cable by loosening the locknut

1

and screwing the adjuster

2

on the brake lever holder all the way in. After adjusting the play, tighten the locknut

1

.

%

Rear brake lever play

B

: 3 5 mm (0.1 0.2 in )

BRAKE FLUID

Inspect every 3 months.

Replace every 2 years.

BRAKE FLUID LEVEL

Place the handlebar straight.

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

When the brake fluid 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 vehicle is filled with a glycol-based brake fluid. Do not use or mix different types of fluid such as silicone-based and petroleum-based fluids. Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or stored

* Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces. Check leakage before riding.

877-999-5686

2-16 PERIODIC MAINTENANCE

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 front brake reservoir with the specified brake fluid to the top of the inspection window or the upper limit line.

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.

Squeeze and release the brake lever several times in rapid succession and hold the lever fully squeezed. Loosen the air bleeder valve for about 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 lever and open the valve. Repeat this process until the fluid flowing into the receptacle contains no air bubbles.

NOTE:

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

#

Close the air bleeder valve and disconnect the hose. Fill the or the upper limit line.

"

PartShark.com

Air bleeder valve: 6 N•m (0.6 kgf-m, 4.4 lb-ft)

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

BRAKE HOSE

Inspect every 6 months.

Replace every 4 years.

Check the brake hoses for leakage, cracks, wear and damage. If any damages are found, replace the brake hoses with new ones.

PERIODIC MAINTENANCE 2-17

TIRES

Inspect every 3 months.

TIRE TREAD CONDITION

Operating the vehicle with excessively worn tires will decrease

PartShark.com

%

Service Limit

Rear 4.0 mm (0.16 in)

$

09900-20805: Tire depth gauge

4.0 mm

(0.16 in)

2-18 PERIODIC MAINTENANCE

TIRE PRESSURE

If the tire pressure is too high or too low, steering will be adversely affected and tire wear will increase. Therefore, maintain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows.

COLD INFLATION TIRE PRESSURE kPa kgf/cm

2 psi

FRONT

REAR

30

25

0.30

0.25

4.4

3.6

VEHICLE LOAD CAPACITY LIMIT: 110 kg (243 lbs)

"

To minimize the possibility of tire damage from over-inflation, we strongly recommended that a manual type air pump be used rather than a high pressure air compressor as found in service stations. When filling air into the tires, never exceed 70 kPa (0.7 kgf/cm†,

10 psi).

"

The standard tire fitted on this vehicle is an AT22

7-10

✩✩

for the front and a AT20 10-9

✩

for the rear.

The use of tires other than those specified may cause instability. It is highly recommended to use the specified tires.

PERIODIC MAINTENANCE 2-19

STEERING

Inspect initially at 1 month and every 3 months thereafter.

Steering system should be adjusted properly for smooth handling of the handlebars and safe running.

TOE-IN

Place the vehicle on level ground.

Make sure the tire pressure for right and left tires is same and set to the proper specification.

Set the front wheels in the straight position.

Place a load of 75 kg (165 lbs) on the seat.

Measure the distance

A

and

B

of the front wheels with a toe-in gauge as shown and calculate the difference

A B

.

%

Toe-in: 5 – 4 mm (0.20 – 0.16 in)

If the toe-in is out of specification, bring it into the specified range. (

!

7-43)

Forward

B

SUSPENSIONS

Inspect every 6 months.

wear or damage. If any damages are found, replace the suspension arm or bushing with a new one. ( one. (

!

7-56)

7-32)

877-999-5686

Inspect the front and rear shock absorbers for oil leakage or damage. If any damages are found, replace them with a new one. (

!

7-31 and -53)

A

2-20 PERIODIC MAINTENANCE

CHASSIS BOLTS AND NUTS

Tighten initially at 1 month and every 3 months thereafter.

Check that all chassis nuts and bolts are tightened to their specified torque. (Refer to page 2-21 and 2-22 for the locations of the following nuts and bolts.)

Item

1

Handlebar clamp bolt

2

Steering shaft holder bolt

3

Steering shaft nut

4

Wishbone arm pivot bolt/nut (Upper and lower)

5

Wheel hub nut (Front)

6

Wheel hub nut (Rear)

7

Wheel set nut (Front and rear)

N•m

23

23

49

65

65

138

50

kgf-m

2.3

2.3

4.9

6.5

6.5

13.8

5.0

8

Steering knuckle nut (Upper and lower)

9

Front shock absorber mounting bolt/nut (Upper and lower)

0

Tie rod end nut

A

Tie rod lock nut

B

Front brake air bleeder valve

C

Front brake caliper mounting bolt

29

60

29

29

6

2.9

6.0

2.9

2.9

0.6

P

Rear axle housing set bolt/nut (RH)

Q

Rear axle housing set bolt/nut (LH)

R

Rear axle housing/final gear case bolt

26

D

Front brake pipe nut (Upper and lower)

E

Front brake master cylinder mounting bolt

F

Front brake hose union bolt (Upper and lower)

G

Front brake disc plate mounting bolt

16

10

23

1.6

1.0

2.3

23 2.3

H

Footrest bolt (M8)

I

Footrest bolt (M10)

26

55

2.6

5.5

J

Rear shock absorber mounting bolt/nut (Upper)

K

Rear shock absorber mounting bolt/nut (Lower)

L

Swingarm pivot bolt/nut

M

Rear brake cam lever bolt/nut

78

60

85

7.8

6.0

8.5

N

Rear brake panel mounting nut

O

Rear brake pedal mounting bolt

11

60

11

1.1

1.1

60

65

65

2.6

6.0

6.5

6.5

19.0

40.0

55.0

43.5

61.5

8.0

43.5

8.0

21.0

21.0

4.4

19.0

11.6

7.0

16.5

16.5

43.5

47.0

47.0

lb-ft

16.5

16.5

35.5

47.0

47.0

99.9

36.0

21.0

43.5

PERIODIC MAINTENANCE 2-21

2-22 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-23

GENERAL LUBRICATION

Lubricate initially at 1 month and every 3 months thereafter.

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

Major lubrication points are indicated below.

PartShark.com

1

Brake lever holder

877-999-5686

5

Brake cam

&)

Grease

*)

Motor oil

2

Throttle lever and cable

6

Brake cable

3

Steering shaft holder

7

Starter cable

4

Brake pedal and cable

8

Gearshift shaft

NOTE:

* Before lubricating each part, remove any rust 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 vehicle has been operated under wet or rainy conditions.

2-24 PERIODIC MAINTENANCE

COMPRESSION PRESSURE CHECK

The compression pressure reading 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 shoud include compression readings for each maintenance service.

%

Compression pressure:

Standard: 1 400 kPa (14.0 kgf/cm†, 199 psi)

Service Limit: 1 200 kPa (12.0 kgf/cm†, 171 psi)

Low compression pressure can indicate any of the following conditions:

* Excessively worn cylinder walls

* Worn piston or piston rings

* Piston rings stuck in grooves

* Poor valve seating

* Ruptured or otherwise defective cylinder head gasket

NOTE:

When the compression pressure goes below specification, check the engine for conditions listed above.

COMPRESSION TEST PROCEDURE

NOTE:

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

* Warm up the engine before testing.

* Make sure that the battery is fully charged.

Test the compression pressure in the following manner:

Remove the spark plug. (

!

2-7)

Install the compression gauge and adaptor in the spark plug hole. Make sure that the connection is tight.

Keep the throttle lever in the fully open position.

Press the starter button and crank the engine for a few seccompression.

$

PartShark.com

09918-02410: Adaptor or

09918-03810: Adaptor

877-999-5686

PERIODIC MAINTENANCE 2-25

OIL PRESSURE CHECK

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

%

Oil pressure:

Above 30 kPa (0.3 kgf/cm†, 4.3 psi)

Below 70kPa (0.7 kgf/cm†, 9.9 psi) at 3 000 r/min, oil temp. at 60 C (140 F)

Low or high oil pressure can indicate any of the following conditions:

LOW OIL PRESSURE

* Clogged oil filter

* Oil leakage from the oil passage

* Damaged O-ring

* Defective oil pump

* Combination of the above items

HIGH OIL PRESSURE

* Engine oil viscosity is too high

* Clogged oil passage

* Combination of the above items

OIL PRESSURE TEST PROCEDURE

Connect the tachometer onto the spark plug high-tension cord.

Remove the oil plug

1

.

Install the oil pressure gauge and adaptor into the main oil gallery.

PartShark.com

Winter: 20 minutes at 2 000 r/min

After warming up the engine, increase the engine speed to

3 000 r/min (observe the tachometer), and read the oil pressure gauge.

$

09915-74511: Oil pressure gauge

09915-74512: Oil pressure gauge adaptor

2-26 PERIODIC MAINTENANCE

INITIAL ENGAGEMENT AND CLUTCH LOCK-UP INSPECTION

The LT-Z250 is equipped with a centrifugal type automatic clutch.

To insure proper performance and longevity of the clutch assemblies, it is essential that the clutches engage smoothly and gradually. Before checking the initial engagement and clutch lock-up, two inspection checks must be performed to thoroughly check the operation of the drive train. Perform the following:

Check the oil level. (

!

2-10)

Warm up the engine.

INITIAL ENGAGEMENT INSPECTION

Connect the tachometer or the multi circuit tester onto the spark plug high-tension cord.

Start the engine.

Shift the gear shift lever to the 1st position.

Slowly open the throttle and note the engine speed (r/min) when the vehicle begins to move forward.

$

09900-25008: Multi circuit tester set or

09900-26006: Tachometer

%

Engagement speed: 1 700 2 100 r/min

If the engagement speed does not coincide with the standard range, inspect the following items for any abnormalities.

* Clutch shoes ...............................................

!

3-40

* Clutch wheel ...............................................

!

3-40

CLUTCH LOCK-UP INSPECTION

fully and not slipping.

PartShark.com

Start the engine.

Shift the gear shift lever to the 5th position.

Apply the front and rear brakes as firmly as possible.

Fully open the throttle for a brief period and note the maximum engine speed sustained during the test cycle.

%

Lock-up speed: 3 100 3 700 r/min

"

Do not apply full power for more than 5 seconds or damage to the clutch or engine may occur.

If the lock-up speed (r/min) does not coincide with the standard range, inspect the following items for any abnormalities.

* Clutch shoes ...............................................

!

3-40

* Clutch wheel ...............................................

!

3-40

ENGINE

CONTENTS

ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE............ 3- 2

ENGINE REMOVAL AND INSTALLATION .................................................. 3- 3

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

ENGINE INSTALLATION ....................................................................... 3- 8

ENGINE DISASSEMBLY .............................................................................. 3-12

ENGINE TOP SIDE................................................................................. 3-12

ENGINE BOTTOM SIDE......................................................................... 3-15

ENGINE COMPONENTS INSPECTION AND SERVICE.............................. 3-23

CYLINDER HEAD COVER ..................................................................... 3-23

CYLINDER HEAD ................................................................................... 3-25

CAMSHAFT ............................................................................................ 3-33

CAM CHAIN TENSION ADJUSTER ...................................................... 3-34

CAM CHAIN TENSIONER AND CAM CHAIN GUIDE ........................... 3-34

CYLINDER .............................................................................................. 3-35

PISTON AND PISTON RING .................................................................. 3-35

CONROD AND CRANKSHAFT.............................................................. 3-38

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

TRANSMISSION ..................................................................................... 3-42

GEARSHIFT FORK ................................................................................ 3-45

GENERATOR COVER............................................................................ 3-45

CLUTCH COVER .................................................................................... 3-46

CRANKCASE ......................................................................................... 3-47

CRANKSHAFT ....................................................................................... 3-50

DRIVE TRAIN ......................................................................................... 3-51

PartShark.com

ENGINE BOTTOM SIDE......................................................................... 3-59

ENGINE 3-1

3

3-2 ENGINE

ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE

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

ENGINE LEFT SIDE

PARTS

Neutral switch

Secondary driven bevel gear

Generator cover

Starter idle gear

Generator

REMOVAL

3-15

3-15

3-15

3-15

3-19

INSTALLATION

3-70

3-69

3-69

3-69

3-63

ENGINE RIGHT SIDE

PARTS

Oil filter

Clutch cover

Clutch

Gearshift

Oil pump drive gear

Oil pump

REMOVAL

3-16

3-16

3-16

3-18

3-18

3-18

INSTALLATION

3-69

3-68

3-65

3-64

3-64

3-64

ENGINE CENTER

PARTS

Starter motor

Cam chain tension adjuster

REMOVAL

3-12

3-13

INSTALLATION

3-76

3-75

Cylinder head

Cylinder

Piston

Cam chain

3-13 Cylinder head cover

Camshaft 3-13

3-14

PartShark.com

3-72

3-70

3-63

3-73

3-72

3-75

ENGINE REMOVAL AND INSTALLATION

ENGINE REMOVAL

Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal procedure.

Drain engine oil. (

!

2-10)

Remove the seat. (

!

7-5)

Disconnect the

-

battery lead wire

1

.

Remove the left and right side covers

2

. (

!

7-5)

Remove the left and right footrest mud guards

3

. (

!

7-7)

PartShark.com

Remove the fuel tank center cover and front fender

4

.

(

!

7-6)

ENGINE 3-3

3-4 ENGINE

Turn the fuel valve to the ON position.

Disconnect the fuel and vacuum hoses.

Remove the carburetor. (

!

5-7)

Disconnect the engine ground lead wire

5

.

Disconnect the neutral switch lead wire coupler

6

, signal pler

8

.

PartShark.com

Remove the left footrest

9

.

Remove the gearshift lever link

0

.

Remove the reverse lock release cable

A

.

Disconnect the spark plug cap.

Remove the right footrest

B

.

877-999-5686

Remove the brake pedal

C

.

ENGINE 3-5

3-6 ENGINE

Loosen the muffler connecting bolt.

Remove the exhaust pipe and gasket.

Disconnect the breather hose

D

.

Remove the starter motor lead wire.

877-999-5686

Remove the rear upper engine mounting nut, bolts and bracket

E

.

Remove the front and rear lower engine mounting nuts and bolts.

Disengage the secondary driven gear shaft from the universal joint.

Remove the right front fender bracket

F

.

Dismount the engine to the right side.

ENGINE 3-7

3-8 ENGINE

ENGINE INSTALLATION

Remount the engine in the reverse order of engine removal.

Pay attention to the following points:

NOTE:

* The engine mounting nuts are self-locking.

* Once the nut has been removed, it is no longer of any use. Be sure to use new nuts, and then tighten them to the specified torque.

@

ITEM

A

BCD

66

N•m kgf-m

23 2.3

PartShark.com lb-ft

16.5

877-999-5686

6.6

48.0

CLUTCH RELEASE ADJUSTMENT

Temporarily install the gear shift lever.

Remove the clutch adjuster cap.

Loosen the clutch release outer guide nuts

1

.

Loosen the locknut

2

.

Turn the adjusting screw

3

clockwise until it stops.

Check that the gearshift lever plays

A

, up and down, are same. If not, set the clutch release outer guide in suitable position.

Fix the clutch release outer guide by tightening the clutch release outer guide nuts

1

.

Gearshift lever

Loosen the locknut

2

.

Tighten the adjusting screw

3

until it stops.

Loosen the adjusting screw

3

1/16 1 /8 turn.

Tighten the locknut

2

to the specified torque while holding the adjusting screw

3

.

"

Locknut

2

: 23 N•m (2.3 kgf-m, 16.5 lb-ft)

Apply engine oil to the O-ring and cap thread lightly.

Tighten the clutch adjuster cap to the specified torque.

"

Clutch adjuster cap: 15 N•m (1.5 kgf-m, 11.0 lb-ft)

ENGINE 3-9

Engage the secondary driven gear shaft to the universal joint.

877-999-5686

Install new gasket as its projections face outside.

3-10 ENGINE

Install a new exhaust pipe/muffler connector

4

into the muffler lip.

NOTE:

Exhaust gas sealer should be applied to both of the inside and outside of the connector

4

.

EXHAUST GAS SEALER: PERMATEX 1372

Apply SUZUKI SUPER GREASE to the O-rings.

#

99000-25030: SUZUKI SUPER GREASE A ( USA)

99000-25010: SUZUKI SUPER GREASE A (Others)

Install the washer

5

.

Install the brake pedal as its slit matches with the punched mark on the shaft.

Tighten the brake pedal mounting bolt to the specified torque.

"

Brake pedal mounting bolt: 11 N•m (1.1 kgf-m, 8.0 lb-ft)

$

"

Apply THREAD LOCK to the bolts and tighten each bolt to the specified torque.

877-999-5686

Adjust the brake pedal play

A

.

%

Brake pedal play

A

: 20 30 mm (0.8 1 .2 in)

ENGINE 3-11

Install the reverse gearshift arm.

%

Reverse gearshift arm angle

B

: 20

Install the gearshift lever.

%

Gearshift arm angle

C

: 35

Adjust the gearshift lever height

D

.

%

Gearshift lever height

D

: 0 10 mm (0 0 .4 in)

Position the carburetor clamps as shown in the illustration.

Left Right

877-999-5686

45ß

Left

Engine side

Air cleaner side

Right

After installing the engine, route the wire harness, cables and hoses properly. (

!

9-11 to -14)

Check the followings.

* Engine oil

!

2-10

* Engine idle speed

!

2-9

* Throttle cable play

!

2-9

3-12 ENGINE

ENGINE DISASSEMBLY

ENGINE TOP SIDE

SPARK PLUG

Remove the spark plug.

&

09930-10121: Spark plug wrench set

STARTER MOTOR

Remove the starter motor.

Remove the valve timing inspection plug

1

and generator cover cap

2

.

CAM CHAIN TENSION ADJUSTER

Remove the spring holder bolt

1

, pin and spring.

Remove the cam chain tension adjuster.

CYLINDER HEAD COVER

Remove the cylinder head cover.

CAMSHAFT

Remove the camshaft end cap

1

.

Flatten the lock washer and remove the camshaft sprocket bolts.

877-999-5686

Remove the dowel pins.

Remove the camshaft

2

and camshaft sprocket

3

.

'

Do not drop the cam chain

4

into the crankcase.

ENGINE 3-13

3-14 ENGINE

Remove the C-ring

5

.

'

Do not drop the C-ring

5

into the crankcase.

CYLINDER HEAD

Remove the cylinder head nuts (M6)

1

.

Loosen the cylinder base nuts (M6)

2

.

Remove the cylinder head nuts (M8) diagonally.

Remove the cylinder head.

NOTE:

If the cylinder head does not come off, lightly tap on the finless portion of it with a plastic hammer.

CYLINDER

guide

1

.

Remove the cylinder.

NOTE:

* Be careful not to drop the dowel pins into the crankcase.

* If the cylinder does not come off, lightly tap on the finless portion of it with a plastic hammer.

PISTON

Remove the piston pin circlip

1

.

Remove the piston pin and piston.

NOTE:

Place a rag under the piston so as not to drop the piston pin circlip into the crankcase.

Remove the cylinder gasket and dowel pins.

ENGINE BOTTOM SIDE

NEUTRAL SWITCH

Remove the neutral switch

1

.

Remove the switch contacts

2

and springs.

SECONDARY DRIVEN BEVEL GEAR

Remove the secondary driven bevel gear cover.

Remove the dowell pins and secondary driven bevel gear assembly

1

.

GENERATOR COVER

holder

1

.

877-999-5686

STARTER IDLE GEAR

Remove the dowel pins and gasket.

Remove the starter idle gear with its shaft and spacer.

ENGINE 3-15

3-16 ENGINE

OIL FILTER

Remove the oil filter cover.

Remove the oil filter and O-ring

1

.

CLUTCH COVER

Remove the clutch cover.

Remove the dowel pins and gasket.

Remove the clutch release ball assembly

1

, inner ball guide

2

, washer

3

and clutch release arm

4

.

CLUTCH

NOTE:

Slightly loosen the clutch spring bolts with holding the clutch shoe nut to facilitate later disassembly.

877-999-5686

While holding the generator rotor with the special tool, remove the clutch shoe nut.

&

09930-44520: Rotor holder

'

Clutch shoe nut has left-hand threads.

Remove the clutch shoes

1

and washer.

Remove the clutch wheel assembly

1

.

Remove the clutch bolts.

Remove the clutch release plate

1

and springs.

Using a chisel, unlock the nut.

Remove the clutch sleeve hub nut with the special tool.

&

877-999-5686

Remove the washer

2

and primary driven gear assembly

3

.

ENGINE 3-17

3-18 ENGINE

GEARSHIFT

Remove the gearshift arm

1

.

Remove the shift cam shaft assembly

2

.

Remove the gearshift cam plate

3

and stopper

4

.

1

and pin

2

.

OIL PUMP DRIVE GEAR

877-999-5686

OIL PUMP

Remove the E-ring.

Remove the oil pump driven gear

1

.

Remove the pin

2

and washer

3

.

Remove the oil pump.

GENERATOR

Remove the generator rotor nut with the special tool.

&

09930-44520: Rotor holder

Install the special tool to the crankshaft end.

&

09930-31921: Rotor remover attachment

Remove the generator rotor with the special tool.

&

877-999-5686

Remove the key

1

.

Remove the starter driven gear

2

.

ENGINE 3-19

3-20 ENGINE

CAM CHAIN

Remove the cam chain.

CRANKCASE

Remove the left crankcase bolts.

Remove the right crankcase bolts.

Separate the crankcase with the special tool.

NOTE: face of the crankcase.

PartShark.com

&

09920-13120: Crankcase separator

OIL SUMP FILTER

Remove the dowel pins.

Remove the oil sump filter

1

.

DRIVE TRAIN/GEARSHIFT CAM

Remove the reverse idle gear assembly

1

.

Remove the gearshift cam

2

Remove the shafts

3

and forks

4

.

Remove the shift cam lock shaft

5

.

7

.

Remove the washers, reverse driven gear

6

and reverse dog

PartShark.com

CRANKSHAFT

Remove the crankshaft with the special tool.

&

09920-13120: Crankcase separator

ENGINE 3-21

3-22 ENGINE

DRIVE BEVEL GEAR

Using a chisel, unlock the nut.

Fit the special tool onto the driveshaft.

&

09930-73150: Output shaft holder

Loosen the secondary drive bevel gear and nut by holding the special tool with a vise.

Remove the secondary drive bevel gear and driveshaft assembly, countershaft assembly.

ENGINE COMPONENTS INSPECTION AND SERVICE

CYLINDER HEAD COVER

DISASSEMBLY

'

Be sure to identify each removed part as to its location, and lay the parts out in groups designated as

Exhaust , Intake , so that each will be restored to the original location during assembly.

Remove the valve inspection caps

1

.

Remove the rocker arm shaft bolts

2

.

Remove the rocker arm shafts

3

.

Remove the rocker arms

4

and wave washers

5

.

ENGINE 3-23

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 (0.002 in)

&

09900-20803: Thickness gauge

cover.

%

PartShark.com

ROCKER ARM SHAFT O.D.

Standard: 11.977 11.995 mm (0.4715 0 .4722 in)

&

09900-20205: Micrometer (0 25 mm)

3-24 ENGINE

ROCKER ARM I.D.

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

%

Rocker arm I.D.

Standard: 12.000 1 2.018 mm (0.4724 0 .4731 in)

&

09900-20605: Dial calipers

REASSEMBLY

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

Install new O-rings

1

to the rocker arm shafts.

Apply engine oil to the rocker arms and shafts.

Install the rocker arms, wave washers and shafts to the cylinder head cover.

Tighten the rocker arm shaft bolts to the specified torque.

"

Rocker arm shaft bolt: 9 N•m (0.9 kgf-m, 6.5 lb-ft)

'

Install the gasket washers to prevent oil leakage.

Install new O-rings to the valve inspection caps.

#

PartShark.com

CYLINDER HEAD

DISASSEMBLY

Remove the intake pipe

1

.

Remove the cam chain tensioner

2

.

Cam chain tentioner inspection (

!

3-34)

Compress the valve spring and remove the valve cotters from the valve stem with the special tools.

&

09916-14510: Valve spring compressor

09916-14910: Attachment

09916-84511: Tweezers

Remove the valve spring retainer and valve spring.

Remove the valve from the other side.

Remove the valve stem seal with long-nose pliers.

NOTE:

PartShark.com

valve guides have to be removed for replacement after inspecting the related parts, carry out the steps shown in the valve guide servicing.

CYLINDER HEAD DISTORTION

Decarbonize the combustion chamber.

Check the gasket surface of the cylinder head for distortion using a straightedge and thickness gauge. Take clearance readings at several places. If any clearance reading exceeds the service limit, replace the cylinder head with a new one.

%

Cylinder head distortion

Service Limit: 0.05 mm (0.002 in)

&

09900-20803: Thickness gauge

ENGINE 3-25

3-26 ENGINE

VALVE STEM RUNOUT

Support the valve with the V-blocks and measure the valve stem runout with the dial gauge, as shown. If the runout exceeds the service limit, replace the valve with a new one.

%

Valve stem runout

Service Limit: 0.05 mm (0.002 in)

&

09900-20701: Magnetic stand

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

09900-21304: V-block

VALVE HEAD RADIAL RUNOUT

Support the valve with the V-blocks and measure the valve head radial runout with the dial gauge, as shown. If the runout exceeds the service limit, replace the valve with a new one.

%

Valve head radial runout

Service Limit: 0.03 mm (0.001 in)

&

09900-20701: Magnetic stand

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

09900-21304: V-block

VALVE FACE WEAR

Visually inspect each valve face for wear or damage. If any abnormal wear is found, replace the respective valve with a new one. Measure the valve head thickness

T

. If the valve head thickness is not within the specified value, replace the value with a new one.

%

Valve head thickness

T

Service Limit: 0.5 mm (0.02 in)

&

09900-20101: Vernier calipers

PartShark.com

pendicular to each other, by positioning the dial gauge as whether the valve or the guide should be replaced with a new one.

X

Y

%

Valve stem deflection (IN & EX)

Service Limit: 0.35 mm (0.14 in)

&

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

09900-20701: Magnetic stand

VALVE STEM WEAR

Measure the valve stem outside diameter with the micrometer. If the outside diameter is not within the specified value, replace the valve with a new one. If the valve stem outside diameter is within specification, but the valve stem deflection is not, replace the valve guide with a new one. After replacing the valve or valve guide, check the deflection and.

%

Valve stem O.D.

Standard (IN) : 5.475 5.4 90 mm (0.2156 0.2 161 in)

(EX) : 5.455 5.4 70 mm (0.2148 0.2 154 in)

&

09900-20205: Micrometer (0 25 mm)

VALVE GUIDE SERVICING

Drive the valve guide out toward the intake or exhaust rocker arm side with the valve guide remover.

&

09916-44910: Valve guide remover/installer

NOTE:

* Discard the removed valve guide.

* Only oversized valve guides are available as replacement parts. (Part No. 11115-05270)

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

&

09916-34561: Valve guide reamer (11.3 mm)

09916-34542: Reamer handle

Install a ring onto each valve guide. Be sure to use new rings.

&

877-999-5686

09916-44910: Valve guide remover/installer

'

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

ENGINE 3-27

3-28 ENGINE

After fitting all valve guides, re-finish their guiding bores with the valve guide reamer. Be sure to clean and oil the guide after reaming.

&

09916-34550: Valve guide reamer (5.5 mm)

09916-34542: Reamer handle

NOTE:

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

VALVE SEAT WIDTH

Coat the valve seat with prussian blue uniformly. Install the valve and attach the valve lapper onto it. Tap the coated seat with the valve face in a rotating manner, in order to obtain a clear impression of the seating contact.

&

09916-10911: Valve lapper set

The ring-like dye impression left on the valve face must be continuous, without any breaks. In addition, the width of the dye ring, which is the valve seat width, must be within the following specification.

%

Valve seat width

W

Standard: 0.88 1.08 mm (0.035 0.043 in)

If the valve seat is out of specification, re-cut the seat.

VALVE SEAT SERVICE

two different angles. The seat contact surface is cut at 45 .

15

45

PartShark.com

INTAKE

N-212

N-608

877-999-5686

&

09916-21111: Valve seat cutter set

EXHAUST

N-121

N-122

Valve seat

09916-24900: Valve seat cutter set

09916-22480: Solid pilot (N-140-5.5)

09916-24450: Solid pilot (N-100-5.52)

09916-24935: Valve seat cutter (N-608)

'

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

ENGINE 3-29

When installing the solid pilot, rotate it slightly. Seat the pilot snugly. Install the 45 cutter, attachment and T-handle.

INITIAL SEAT CUT

Descale and clean up the seat with the 45 cutter. 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 camshaft.

If the contact area

W

is too high on the valve, or if it is too

TOP NARROWING CUT

Too high or too wide contact surface

877-999-5686

3-30 ENGINE

FINAL SEAT CUT

If the contact area

W

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

NOTE:

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

Too low or too narrow contact surface on the valve

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. (

!

2-5)

Clean and assemble the head and valve components. Fill the intake and exhaust ports with gasoline to check for leaks.

If any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from sealing.

(

Always use extreme caution when handling gasoline.

VALVE STEM END CONDITION

877-999-5686

Inspect the valve stem end face for pitting and wear. If pitting or wear of the stem end face are present, the valve stem end may be resurfaced, providing that the length

1

will not be reduced to less than the service limit. If this length becomes less than the service limit, the valve must be replaced.

%

Valve stem end length

Service Limit: 2.5 mm (0.10 in)

ENGINE 3-31

VALVE SPRING

The force of the coil spring keeps the valve seat tight. Weakened spring result in reduced engine power output, and often account for the chattering noise coming from the valve mechanism.

Check the 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 valve spring is not within specification, replace both the inner and outer springs as a set.

%

Valve spring free length (IN & EX)

Service Limit: 43.0 mm (1.69 in)

%

Valve spring tension (IN & EX)

Standard: 256 29 4 N/36.6 mm

(26.1 30.0 kgf/36.6 mm,

57.5 6 6.1 lbs/1.44 in)

&

09900-20101: Vernier calipers

REASSEMBLY

Install each valve spring seat.

Apply engine oil to each oil seal and press-fit them into position.

'

Do not reuse the oil seal.

256 294 N

36.6 mm

Insert the valves, with their stems coated with molybdenum oil break.

)

'

PartShark.com

When inserting each valve into the valve guides, make sure not to damage the lip of the oil seal.

Install the valve spring with the smaller pitch portion

A

facing the cylinder head.

A

Smaller pitch portion.

B

Larger pitch portion.

Cylinder head

3-32 ENGINE

Put on the valve spring retainer, and using the valve lifter, press down the springs, fit the cotter halves to the stem end, and release the lifter to allow the cotter

1

to wedge in between retainer and stem. Be sure that the rounded lip

2

of the cotter fits snugly into the groove

3

in the stem end.

&

09916-14510: Valve spring compressor

09916-14910: Valve spring compressor attachment

09916-84511: Tweezers

'

Be sure to restore each spring, valve and spring retainer to their original positions.

INTAKE PIPE

When installing the intake pipe, apply SUZUKI SUPER

GREASE to the O-ring.

#

99000-25030: SUZUKI SUPER GREASE A ( USA)

99000-25010: SUZUKI SUPER GREASE A (Others)

'

Use the new O-ring to prevent sucking air from the joint.

NOTE:

Make sure that the protrusion

A

faces upward.

Install the intake pipe

1

and cam chain tensioner

2

.

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

877-999-5686

"

Cam chain tensioner mounting bolt:

13 N•m (1.3 kgf-m, 9.5 lb-ft)

CAMSHAFT

The camshaft should be checked for wear and also for runout of cams and journals if the engine has been noted to produce abnormal noise or vibration or to lack output power. Any of these malconditions could be caused by a worn camshaft.

CAMSHAFT CAM WEAR

Worn-down cams are often the cause of mistimed valve operation resulting in reduced power output.

Measure the cam height

H

with the micrometer. If the cams are worn to the service limit, replace the camshaft with a new one.

%

Cam height

H

Service Limit (IN) : 33.480 mm (1.3181 in)

(EX) : 32.690 mm (1.2870 in)

&

09900-20202: Micrometer (25 50 mm)

CAMSHAFT JOURNAL WEAR

Determine whether each journal is worn down to the limit or not by measuring camshaft journal oil clearance with the camshaft installed. Use the plastigauge to read the clearance, which is specified as follows:

%

Camshaft journal oil clearance

Service Limit: 0.150 mm (0.0059 in)

&

09900-22302: Plastigauge

NOTE:

To properly measure the oil clearance with plastigauge, all gasket material must be removed from fitting surfaces of cylinder head and cover. Do not apply SUZUKI BOND until after the oil clearance has been determined.

"

Tighten the cylinder head cover bolts evenly and diagonally to

Cylinder head cover bolt: 10 N•m (1.0 kgf-m, 7.3 lb-ft)

NOTE:

877-999-5686

pressed plastigauge with envelope scale. This measurement should be taken at the widest part of the compressed plastigauge.

ENGINE 3-33

3-34 ENGINE

If the camshaft journal oil clearance measured exceeds the limit, measure the outside diameter of camshaft.

Replace either the cylinder head set or the camshaft if the clearance is incorrect.

%

Camshaft journal O.D.

Standard: 21.959 21.976 mm

(0.8645 0 .8652 in)

&

09900-20205: Micrometer (0 2 5 mm)

CAMSHAFT RUNOUT

Measure the camshaft runout with the special tools. If the runout exceeds the service limit, replace the camshaft with a new one.

%

Camshaft runout (IN & EX)

Service Limit: 0.10 mm (0.004 in)

&

09900-20607: Dial gauge (1/100, 10 mm)

09900-20701: Magnetic stand

09900-21304: V-block (100 mm)

CAM CHAIN TENSION ADJUSTER

Check that the push rod slides smoothly with unlocking the ratchet mechanism

1

. If any stickiness is noted or ratchet mechanism is faulty, replace the cam chain tension adjuster with a new one.

CAM CHAIN TENSIONER AND CAM CHAIN

GUIDE

PartShark.com

new one.

ENGINE 3-35

CYLINDER

CYLINDER DISTORTION

Check the gasket surface of the cylinder for distortion with a straightedge and the thickness gauge, taking a clearance reading at several places as indicated. If any clearance reading exceeds the service limit, replace the cylinder with a new one.

%

Cylinder distortion

Service Limit: 0.05 mm (0.002 in)

&

09900-20803: Thickness gauge

CYLINDER BORE

Inspect the cylinder wall for any scratches, nicks or other damage. Measure the cylinder bore diameter at six places.

%

Cylinder bore

Service Limit: 66.090 mm (2.6020 in)

&

09900-20508: Cylinder gauge set

PISTON AND PISTON RING

PISTON DIAMETER

Measure the piston diameter with the micrometer at 18 mm

(0.71 in) from the skirt end.

If the piston diameter is less than the service limit, replace the piston with a new one.

%

Piston diameter

Service Limit: 65.880 mm (2.5937 in)

&

09900-20203: Micrometer (50 75 mm)

As a result of the aforesaid measurement, if the piston to cylinpiston.

PartShark.com

and use an oversize piston, or replace both of the cylinder and

%

Piston to cylinder clearance

Service Limit: 0.12 mm (0.0047 in)

Piston oversize: 0.5

18 mm (0.71 in)

3-36 ENGINE

PISTON RING TO GROOVE CLEARANCE

Measure the side clearances of the 1st and 2nd piston rings with the thickness gauge. If any clearance reading exceeds the service limit, replace both the piston and piston rings.

%

Piston ring to groove clearance

Service Limit (1st) : 0.18 mm (0.0071 in)

(2nd): 0.15 mm (0.0059 in)

%

Piston ring groove width

Standard (1st) : 1.01 1 .03 mm (0.0398 0 .0406 in)

(2nd): 1.21 1.23 mm (0.0476 0.0 484 in)

(Oil) : 2.01 2 .03 mm (0.0791 0 .0799 in)

%

Piston ring thickness

Standard (1st) : 0.97 0.99 mm

(0.038 0 .039 in)

(2nd): 1.17 1.19 mm

(0.046 0 .047 in)

&

09900-20803: Thickness gauge

09900-20205: Micrometer (0 2 5 mm)

PISTON RING FREE END GAP AND PISTON RING END GAP

At first measure the piston ring free end gap with the vernier calipers and then fit the piston ring squarely into the cylinder and measure the piston ring end gap with the thickness gauge.

If any measurement exceeds the service limit, replace the piston ring with a new one.

%

Piston ring free end gap

%

Service Limit (1st) : 7.0 mm (0.28 in)

(2nd): 6.1 mm (0.24 in)

PartShark.com

(2nd): 0.50 mm (0.020 in)

&

09900-20101: Vernier calipers

09900-20803: Thickness gauge

ENGINE 3-37

Oversize piston ring

The following oversize piston rings are used. They bear the following identification numbers.

SIZE

0.5 mm O.S.

1st

50

2nd

50

Oversize oil ring

The following oversize oil ring is available as optional parts.

They bear the following identification mark.

SIZE

STD

0.5 mm O.S.

COLOR

NIL

Painted Red

Oversize side rail

Just measure outside diameter to identify the side rail as there is no mark or numbers on it.

Paint

PISTON PIN AND PIN BORE

Measure the piston pin bore diameter with the small bore gauge.

If the diameter exceeds the service limit, replace the piston with a new one.

%

Piston pin bore I.D.

Service Limit: 16.030 mm (0.6311 in)

&

09900-20602: Dial gauge (1/1 000 mm, 1 mm)

09900-22401: Small bore gauge (10 1 8 mm)

Measure the piston pin outside diameter at three positions with the micrometer. If any measurement exceeds the service limit,

%

PartShark.com

&

09900-20205: Micrometer (0 25 mm)

0.5 mm O.S.

Oil ring spacer

3-38 ENGINE

CONROD AND CRANKSHAFT

CONROD SMALL END I.D.

Measure the conrod small end inside diameter with the small bore gauge. If the conrod small end inside diameter exceeds the service limit, replace the conrod with a new one.

%

Conrod small end I.D.

Service Limit: 16.040 mm (0.6315 in)

&

09900-20605: Dial calipers (10 34 mm)

09900-22401: Small bore gauge (10 1 8 mm)

CONROD DEFLECTION

Wear of the conrod big end can be estimated by checking the movement of the conrod small end. This method can also be used to check the extent of wear on the parts of the conrod big end.

%

Conrod deflection

Service Limit: 3.0 mm (0.12 in)

&

09900-20701: Magnetic stand

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

09900-21304: V-block

CONROD BIG END SIDE CLEARANCE

Slide the conrod big end to one side and measure the side clearance with the thickness gauge. If the clearance exceeds the service limit, replace the crankshaft assembly with a new one or bring the deflection and the side clearance within the service limit by replacing the worn parts (conrod, big end bearing, crank pin, etc.) with new ones.

%

Conrod big end side clearance

&

Service Limit: 1.0 mm (0.04 in)

PartShark.com

crankshaft runout with the dial gauge. If the runout exceeds the service limit, correct or replace the crankshaft with a new one.

%

Crankshaft runout

Service Limit: 0.08 mm (0.003 in)

&

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

09900-20701: Magnetic stand

09910-21304: V-block set (100 mm)

CLUTCH

CLUTCH DRIVE PLATES

NOTE:

Wipe off engine oil from the clutch drive plates with a clean rag.

Measure the thickness of drive plates with a vernier calipers.

If each drive plate is not within the standard range, replace it with a new one.

%

Drive plate thickness

Standard: 2.7 2.9 mm (0.106 0. 114 in)

&

09900-20101: Vernier calipers

Measure the claw width of drive plates with a vernier calipers.

Replace the drive plates found to have worn down to the limit.

%

Drive plate claw width

Service Limit: 11.0 mm (0.43 in)

&

09900-20101: Vernier calipers

CLUTCH DRIVEN PLATES

NOTE:

Wipe off engine oil from the clutch driven plates with a clean rag.

Measure each driven plate for distortion with a thickness gauge and surface plate.

Replace driven plates which exceed the limit.

%

Driven plate distortion

&

Service Limit: 0.10 mm (0.004 in)

CLUTCH SPRING

PartShark.com

pers, and compare the length with the specified limit.

Replace all the springs if any spring is not within the limit.

%

Clutch spring free length

Service Limit: 27.5 mm (1.08 in)

&

09900-20101: Vernier calipers

ENGINE 3-39

3-40 ENGINE

CLUTCH SHOES

Inspect the clutch shoes for chips, cracks, uneven wear, and heat discoloration. Also, check the depth of the grooves on the clutch shoes. If there is no groove at any part of the shoes, replace the shoes as a set.

NOTE:

The clutch shoes must always be changed as a set.

ONE-WAY CLUTCH

Rotate the inner race by hand to inspect that the inner race turns in one direction only and never turns in the opposite direction. If the inner race turns in both directions or is locked, replace the one-way clutch with a new one.

CLUTCH WHEEL

Remove the inner race and one-way clutch.

Inspect the condition of the clutch wheel inner surface for scuffs, scratches, cracks or uneven wear. If any damages are found, replace the clutch wheel with a new one.

STARTER CLUTCH

with the special tool.

&

09930-44520: Rotor holder

Install the starter clutch in the proper direction.

NOTE:

* When installing the starter clutch onto the rotor, make sure that the flange side

A

of the one way clutch faces to the rotor.

* The arrow mark

B

must face to the engine side.

Apply engine oil to the starter clutch.

Apply THREAD LOCK SUPER to the bolts, and then tighten them to the specified torque with a offset wrench.

"

Starter clutch bolt: 26 N•m (2.6 kgf-m, 19.0 lb-ft)

*

99000-32030: THREAD LOCK SUPER 1303

&

09930-44520: Rotor holder

Install the starter driven gear to the starter clutch.

Check that the starter driven gear turns only in counter clockwise.

If there is anything unusual, replace the one way clutch.

Check the starter driven gear bearing. If there is anything unusual, replace the bearing.

Remove the bearing with the special tool.

&

09913-70210: Bearing installer set

Install the bearing with the special tool.

&

877-999-5686

ENGINE 3-41

3-42 ENGINE

TRANSMISSION

DISASSEMBLY

Insert the special tool between the 2nd drive gear and 4th drive gear.

Remove the 2nd drive gear by a hydraulic press.

&

09950-81910: Remover

Disassemble the transmission as shown.

1

Reverse driven gear

2

Reverse gear dog

3

1st driven gear

4

5th driven gear

5

3rd driven gear

6

4th driven gear

7

2nd driven gear

8

Driveshaft

9

Countershaft

0

5th drive gear

A

3rd drive gear

B

4th drive gear

C

2nd drive gear

D

Reverse idle gear

E

Reverse idle shaft

REASSEMBLY

Assemble the transfer in the reverse order of disassembly. Pay attention to the following points:

NOTE:

* Always use new snap rings.

* Before installing the gears, coat lightly engine oil to the shafts and gears.

'

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

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

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

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

Thrust

Sharp edge

Install the clutch sleeve hub nut

1

onto the right end of the countershaft.

ENGINE 3-43

Apply THREAD LOCK SUPER to the internal face of the 2nd drive gear.

Install the 2nd drive gear by a hydraulic press and special tool.

*

99000-32030: THREAD LOCK SUPER 1303

&

09913-70210: Bearing installer set

NOTE:

After installing the 2nd drive gear, check the 4th drive gear spins smoothly with your fingers.

3-44 ENGINE

When installing the bushings, align the shaft hole with the bushing hole.

GEARSHIFT FORK

SHIFT FORK TO GROOVE CLEARANCE

Clearance for each gearshift fork plays an important role in the smoothness and positiveness of the shifting process.

Measure the gearshift fork clearance in the groove of its respective gear with the thickness gauge.

If the clearance exceeds specification, replace the fork, its respective gear, or both.

%

Shift fork to groove clearance

Standard: 0.10 0.30 mm (0.004 0.012 in)

Service Limit: 0.50 mm (0.020 in)

&

09900-20803: Thickness gauge

09900-20101: Vernier calipers

%

Shift fork groove width

Standard: 4.50 4.60 mm (0.177 0.181 in)

%

Shift fork thickness

Standard: 4.30 4.40 mm (0.169 0.173 in)

877-999-5686

GENERATOR COVER

DISASSEMBLY

Remove the generator stator.

REASSEMBLY

Install the generator stator.

Tighten the generator stator bolts in the specified torque.

"

Generator stator bolt: 7 N•m (0.7 kgf-m, 5.0 lb-ft)

ENGINE 3-45

3-46 ENGINE

CLUTCH COVER

DISASSEMBLY

Remove the clutch release outer guide

1

.

Remove the bearing with the special tool.

&

09921-20240: Bearing remover set

NOTE:

If there is no abnormal noise, the bearing removal is not necessary.

INSPECTION

Rotate the balls by hand to inspect for an abnormal noise and a smooth rotation. Replace the clutch release ball assembly if there is anything unusual.

REASSEMBLY

&

09913-70210: Bearing installer set

NOTE:

877-999-5686

Install the clutch release outer guide

1

.

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.

BEARING REMOVAL

Remove the bearing retainers.

Play

ENGINE 3-47

Play

Remove the bearings with the special tools.

&

09921-20240: Bearing remover set

'

PartShark.com

09930-30104: Sliding shaft

The removed bearings should be replaced with new ones.

3-48 ENGINE

BEARING INSTALLATION

Install the bearings with the special tool.

&

09913-70210: Bearing installer set

Install the bearing retainers.

NOTE:

When installing the bearing retainers, apply a small quantity of

THREAD LOCK to the screws.

$

09900-32050: THREAD LOCK 1342

OIL SEAL REMOVAL AND INSTALLATION

Remove the oil seal.

'

Replace the removed oil seal with a new one.

Apply SUZUKI SUPER GREASE to the oil seal.

#

99000-25030: SUZUKI SUPER GREASE A ( USA)

99000-25010: SUZUKI SUPER GREASE A ( Others)

NOTE:

When installing the oil seal, the stamped mark on the oil seal must face outside.

Install the oil seal with the special tool.

&

09913-70210: Bearing installer set

ENGINE MOUNTING RUBBER AND INSTALLATION

Remove and install the engine mounting rubber with the special tool.

&

09913-70210: Bearing installer set

ENGINE 3-49

OIL JET INSTALLATION

Install the new oil jet in the proper direction.

Inside

3-50 ENGINE

CRANKSHAFT

DISASSEMBLY

1

Crankshaft (R)

2

Crank pin

3

Bearing

4

Conrod

5

Crankshaft (L)

REASSEMBLY

Determine the width between the webs referring to the figure when rebuilding the crankshaft.

%

PartShark.com

DRIVE TRAIN

SECONDARY BEVEL GEARS CONSTRUCTION

ENGINE 3-51

PartShark.com

1

Bearing

2

Shim

3

Secondary bevel drive gear

4

Washer

5

Washer

6

Secondary bevel driven gear

7

Shim

8

Bearing

9

Secondary bevel gear shaft

0

Bearing

A

Oil seal

B

O-ring

C

Water proof cover

D

Snap ring

@

ITEM

A

,

B

N•m kgf-m

100 10.0

lb-ft

72.5

3-52 ENGINE

SECONDARY DRIVEN BEVEL GEAR REMOVAL

The following components must be removed in the described order before removing the secondary driven bevel gear.

NOTE:

Refer to the following pages for the details of each step.

Remove the rear wheel. (

!

7-11)

Remove the swingarm. (

!

7-56)

Remove the universal joint.

Remove the secondary driven bevel gear.

SECONDARY DRIVEN BEVEL GEAR DISASSEMBLY

Remove the water proof cover

1

by removing the snap ring.

&

09900-06107: Snap ring pliers

Remove the oil seal

2

and bearing

3

.

Using a chisel, unlock the nut.

Remove the driven bevel gear shaft by holding the universal joint with a vise.

PartShark.com

Remove the washer

4

, bevel gear

5

, shim

6

and bearing

7

.

INSPECTION

Inspect the removed parts for the following abnormalities.

* Drive and driven bevel gears damage or wear

* Improper tooth contact

* Abnormal noise of bearings

* Bearing damage or wear

* Oil seal damage or wear

SECONDARY DRIVEN BEVEL GEAR REASSEMBLY

Install the bearing.

NOTE:

Pay attention to the direction of the bearing.

Install the shim

1

, driven gear and washer

2

.

Fit the universal joint onto the driven bevel gear shaft.

Tighten the driven bevel gear nut to the specified torque.

"

Secondary driven bevel gear nut:

PartShark.com

Install the bearing.

NOTE:

Pay attention to the direction of the bearing.

ENGINE 3-53

3-54 ENGINE

Apply 4 5 gram of WATER RESISTANCE GREASE to the outside of the seal lip groove.

Apply SUZUKI SUPER GREASE to the seal lip groove and install it.

+

99000-25160: WATER RESISTANCE GREASE

#

99000-25030: SUZUKI SUPER GREASE A ( USA)

99000-25010: SUZUKI SUPER GREASE A (Others)

Apply SUZUKI SUPER GREASE to the O-ring and install the water proof cover.

#

99000-25030: SUZUKI SUPER GREASE A ( USA)

99000-25010: SUZUKI SUPER GREASE A (Others)

Install the snap ring.

&

09900-06107: Snap ring pliers

ENGINE 3-55

SECONDARY GEAR SHIMS ADJUSTMENT

Remove the secondary bevel gear cover.

Hold the bearings with the special tool.

&

09921-21910: Bearing holder

Set a dial gauge on the driven bevel gear as shown.

Measure the backlash by turning the driven bevel gear shaft in

PartShark.com

Refer to the chart at the right for appropriate shim thickness.

%

Bevel gear backlash

Standard: 0.03 0.15 mm (0.001 0.006 in)

For driven bevel gear (

:

3-58)

Part No.

09181-25051

09181-25052

09181-25053

09181-25054

09181-25055

Shim thickness

0.60 mm (0.0236 in)

0.65 mm (0.0256 in)

0.70 mm (0.0276 in)

0.75 mm (0.0295 in)

0.80 mm (0.0315 in)

09181-25056 0.85 mm (0.0335 in)

NOTE:

Adjust the backlash by referring to the chart at the right and using the thickness of the removed shims as a guide.

09181-25057

09181-25058

0.90 mm (0.0354 in)

0.95 mm (0.0374 in)

09181-25059 1.00 mm (0.0394 in)

Backlash

Under 0.03 mm

(0.001 in)

0.03 0.15 mm

(0.001 0.006 in)

Over 0.15 mm

(0.006 in)

Shim adjustment

Decrease shim thickness

Correct

09181-25060

09181-25061

09181-25062

09181-25063

Increase shim thickness

1.05 mm (0.0413 in)

1.10 mm (0.0433 in)

1.15 mm (0.0453 in)

1.20 mm (0.0472 in)

3-56 ENGINE

TOOTH CONTACT

After backlash adjustment is carried out, the tooth contact must be checked. Pay attention to the following procedures:

Remove the driven bevel gear.

Clean and degrease several teeth of the drive and driven bevel gears.

Apply a coating of machinist s layout dye or paste to several teeth of the driven bevel gear.

Install the driven bevel gear.

Rotate the driven bevel gear several turns in both directions.

Remove the driven bevel gear and inspect the coated teeth of the drive bevel gear. The tooth contact pattern should be as shown in

1

,

2

and

3

.

If tooth contact is found to be correct (example

2

), go to the

ENGINE REASSEMBLY section on page 3-59 to complete installation.

1

Incorrect (contact at tooth top)

2

Correct

3

Incorrect (contact at tooth root)

If tooth contact is found to be incorrect (examples

1

and

3

), the shim thickness between the drive bevel gear and driven bevel gear must be changed and the tooth contact rechecked until correct.

'

1

2

3

Make sure to check the backlash after the tooth contact has been adjusted, since it may have changed.

Adjust the tooth contact and backlash until they are both within specification. If the correct tooth contact cannot be maintained when adjusting the backlash, replace the drive and driven bevel gears.

Tooth contact

PartShark.com

Decrease shim thickness Decrease shim thickness Contact at tooth root

3

For drive bevel gear (

:

3-58)

Part No.

24935-19B00-025: 0.25 mm (0.0098 in)

24935-19B00-030: 0.30 mm (0.0118 in)

24935-19B00-035: 0.35 mm (0.0138 in)

24935-19B00-090

24935-19B00-095

24935-19B00-100

24935-19B00-105

24935-19B00-110

24935-19B00-115

Shim thickness

0.25+0.25=0.50 mm (0.0197 in)

0.25+0.30=0.55 mm (0.0217 in)

0.30+0.30=0.60 mm (0.0236 in)

0.30+0.35=0.65 mm (0.0256 in)

0.35+0.35=0.70 mm (0.0276 in)

0.25+0.25+0.25=0.75 mm (0.0295 in)

0.25+0.25+0.30=0.80 mm (0.0315 in)

0.25+0.25+0.35=0.85 mm (0.0335 in)

0.90 mm (0.0354 in)

0.95 mm (0.0374 in)

1.00 mm (0.0394 in)

1.05 mm (0.0413 in)

1.10 mm (0.0433 in)

1.15 mm (0.0453 in)

ENGINE 3-57

3-58 ENGINE

REASSEMBLY INFORMATION

List of shims

B

available for the driven bevel gear side

Part No.

09181-25051

09181-25052

09181-25053

09181-25054

09181-25055

09181-25056

09181-25057

09181-25058

09181-25059

09181-25060

09181-25061

09181-25062

09181-25063

Shim thickness

0.60 mm (0.0236 in)

0.65 mm (0.0256 in)

0.70 mm (0.0276 in)

0.75 mm (0.0295 in)

0.80 mm (0.0315 in)

0.85 mm (0.0335 in)

0.90 mm (0.0354 in)

0.95 mm (0.0374 in)

1.00 mm (0.0394 in)

1.05 mm (0.0413 in)

1.10 mm (0.0433 in)

1.15 mm (0.0453 in)

1.20 mm (0.0472 in)

List of shims

A

available for the drive bevel gear side

Part No.

24935-19B00-025: 0.25 mm (0.0098 in)

Shim thickness

0.25+0.25=0.50 mm (0.0197 in)

0.25+0.30=0.55 mm (0.0217 in)

0.30+0.30=0.60 mm (0.0236 in)

24935-19B00-030: 0.30 mm (0.0118 in)

0.30+0.35=0.65 mm (0.0256 in)

0.35+0.35=0.70 mm (0.0276 in)

24935-19B00-035: 0.35 mm (0.0138 in)

24935-19B00-090

24935-19B00-095

24935-19B00-100

24935-19B00-105

0.25+0.25+0.25=0.75 mm (0.0295 in)

0.25+0.25+0.30=0.80 mm (0.0315 in)

PartShark.com

@

ITEM

12

N•m kgf-m

100 10.0

lb-ft

72.5

ENGINE REASSEMBLY

Reassemble the engine in the reverse order of disassembly.

Pay special attention to the following points:

NOTE:

Apply engine oil to each running and sliding part before reassembling.

ENGINE BOTTOM SIDE

DRIVE TRAIN

Install the driveshaft and countershaft assembly.

DRIVE BEVEL GEAR

Install the shim

1

.

Install the drive bevel gear and washer

2

.

Fit the special tool onto the driveshaft.

&

09930-73150: Output shaft holder

PartShark.com

Tighten the secondary drive bevel gear nut to the specified torque by holding the special tool with a vise.

"

Secondary drive bevel gear nut:

100 N•m (10.0 kgf-m, 72.5 lb-ft)

Stake the nut with a center punch.

ENGINE 3-59

3-60 ENGINE

CRANKSHAFT

When mounting the crankshaft in the crankcase, it is necessary to pull its left end into the crankcase with the special tool.

NOTE:

Use proper bars.

&

09910-32812: Crankshaft installer

Install the reverse dog and washer

1

.

Install the reverse driven gear and washer

2

.

Reassemble the shift cam lock shaft.

877-999-5686

Install the shift cam lock shaft by fitting the spring end to the stopper properly.

Install the gearshift cam.

Install the gearshift forks and shafts as shown.

NOTE:

Each fork differs in shape.

1

For reverse/1st gear

2

For 2nd/3rd gear

3

For 4th/5th gear

Install the reverse idle gear shaft

4

.

Install the snap ring

5

, washer

6

and spacer

7

.

8

and washer

9

.

Install the reverse idle gear

877-999-5686

OIL SUMP FILTER

Clean the oil sump filter by using compressed air.

ENGINE 3-61

3-62 ENGINE

Install the oil sump filter as its projection

A

faces upward.

CRANKCASE

Wipe the crankcase mating surfaces (both surfaces) with a cleaning solvent.

Fit the dowel pins onto the left half on the crankcase.

Apply engine oil to the conrod big end and gears.

Apply SUZUKI BOND to the mating surface of the right crankcase.

,

99104-31140: SUZUKI BOND 1207B (USA)

-

99000-31110: SUZUKI BOND 1215 (Others)

Assemble the crankcase within a few minutes.

NOTE:

Fit the clamp to the bolt

A

.

"

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

ENGINE 3-63

CAM CHAIN

Install the cam chain.

GENERATOR

Install the starter driven gear

1

.

Install the key

2

.

NOTE:

PartShark.com

Degrease the tapered portion of the generator rotor assembly wipe off the oily or greasy matter to make these surfaces completely dry.

Install the generator rotor and tighten the generator rotor nut to the specified torque with the special tool.

"

Generator rotor nut: 160 N•m (16.0 kgf-m, 115.5 lb-ft)

&

09930-44520: Rotor holder

3-64 ENGINE

OIL PUMP

Install the oil pump.

Install the washer

1

and pin

2

.

Install the oil pump driven gear and E-ring.

OIL PUMP DRIVE GEAR

Install the pin

1

.

Install the oil pump drive gear.

NOTE:

Flange side of the gear is positioned inside.

GEARSHIFT

NOTE:

Install the spring

1

PartShark.com

Install the the gearshift cam plate

4

.

ENGINE 3-65

Apply THREAD LOCK to the gearshift cam bolt and install the gearshift cam plate guide.

$

99000-32050: THREAD LOCK 1342

Install the gearshift cam shaft assembly so that the stopper

5 comes between the spring ends

6

.

Install the washer

7

and gearshift arm.

CLUTCH

Install the clutch drive/driven plates one by one onto the clutch sleeve hub

1

.

877-999-5686

DRIVEN PLATE ................. 5 pcs

NOTE:

The gray drive plate should be installed at the last.

Black (Cork)

Gray (Paper)

3-66 ENGINE

Install the clutch pressure plate

2

.

Align the clutch drive plates in line to facilitate later assembly.

Install the washer

3

onto the countershaft.

Install the primary driven gear assembly.

Install the washer

4

.

Install the clutch sleeve hub assembly into the primary driven gear assembly.

877-999-5686

Install the washer and clutch sleeve hub nut.

NOTE:

The convex side of the washer faces outside.

INSIDE

OUTSIDE

Washer

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

"

Clutch sleeve hub nut: 100 N•m (10.0 kgf-m, 72.5 lb-ft)

&

09920-53730: Clutch sleeve hub holder

Stake the clutch sleeve hub nut with a center punch.

Install the clutch springs and clutch release plate.

Tighten the clutch spring bolts diagonally.

Install the one-way clutch onto the clutch wheel with the

➞

Install the one-way clutch inner race with the groove inside.

A

facing

877-999-5686

Install the clutch wheel assembly.

ENGINE 3-67

3-68 ENGINE

Install the clutch shoes.

Install the washer as its convex side faces outside.

Before installing the clutch shoe nut, apply engine oil to the thread and inside surface of the nut.

INSIDE

OUTSIDE

Washer

While holding the generator rotor with the special tool, tighten the clutch shoe nut to the specified torque.

&

09930-44520: Generator rotor holder

'

The clutch shoe nut has left-hand threads.

"

Clutch shoe nut: 140 N•m (14.0 kgf-m, 101.5 lb-ft)

Install the clutch release arm

1

and washer

2

clutch release ball inner guide

3

and release ball assembly

4

.

CLUTCH COVER

Install the clutch cover.

OIL FILTER

Before installing the oil filter, fit new O-rings and apply engine oil lightly to them.

Install the spring

1

and oil filter

2

.

'

Use new O-rings to prevent oil leakage.

STARTER IDLE GEAR

Install the idle driven gear

1

, shaft

2

and spacer

3

.

GENERATOR COVER

Install the dowel pins and new gasket.

Install the reverse lock release cable holder

4

and tighten the

PartShark.com

SECONDARY DRIVEN BEVEL GEAR

Install the secondary driven bevel gear shaft assembly

1

.

Install the dowel pins.

ENGINE 3-69

3-70 ENGINE

Apply SUZUKI BOND to the mating surface of the secondary bevel gear cover.

,

99104-31140: SUZUKI BOND 1207B (USA)

-

99000-31110: SUZUKI BOND 1215 (Others)

Install the secondary bevel gear cover.

NEUTRAL SWITCH

Install the springs and switch contacts.

Fit new O-ring and install the neutral switch

1

.

Tighten the neutral switch bolts to the specified torque.

"

Neutral switch bolt: 7 N•m (0.7 kgf-m, 5.0 lb-ft)

ENGINE TOP SIDE

PISTON

ring.

PartShark.com

NOTE:

Side designations, top and bottom, are not applied to the spacer and side rails: Those can be positioned each either way.

'

When installing the spacer, be careful not to allow its two ends to overlap in the groove.

INCORRECT

CORRECT

ENGINE 3-71

Install the 2nd ring

3

and the 1st ring

4

.

NOTE:

1st ring and 2nd ring differ in shape.

1st ring has letter R marked on the side. Be sure to bring the marked side to the top when fitting it to the piston.

1st ring

Position the gaps of the three rings as shown. Before inserting the piston into the cylinder, check that the gaps are so located.

2nd ring

Lower side

rail

EX

Upper side

rail

Apply engine oil to the piston pin.

NOTE:

PartShark.com

head is located to the exhaust side.

IN

1st ring

Spacer

Place a cloth beneath the piston, install the circlip

5

.

'

Use new piston pin circlips to prevent circlip failure with bent ones.

3-72 ENGINE

CYLINDER

Fit the dowel pins and new gasket

1

.

'

Use a new gasket to prevent gas leakage.

NOTE:

* The dowel pins are identified by their length.

* Shorter ones

A

are for cylinder base.

* Apply engine oil to the piston ring grooves and cylinder wall.

Hold each piston ring with proper position, insert the piston into the cylinder.

!

'

When installing the cylinder and cylinder head, pull the cam chain upward, or the chain will be caught between the crankcase and cam drive sprocket.

Tighten the cylinder base nuts (M6) temporarily.

NOTE:

Fit the clamp under the nut

B

.

877-999-5686

CYLINDER HEAD

Install the cam chain guide

1

.

Fit the dowel pins and new cylinder head gasket

2

.

'

Use new gasket to prevent gas leakage.

Install the cylinder head.

Install the washers and cylinder head nuts (M8) as shown.

Tighten the cylinder head nuts (M8) diagonally to the specified torque.

"

Cylinder head nut (M8): 23 N•m (2.3 kgf-m, 16.5 lb-ft)

Tighten the cylinder base nuts (M6)

3

and head nuts (M6)

4 to the specified torque.

"

Cylinder base nut (M6): 10 N•m (1.0 kgf-m, 7.0 lb-ft)

Cylinder head nut (M6): 10 N•m (1.0 kgf-m, 7.0 lb-ft)

CAMSHAFT

Turn the crankshaft until the TDC line

A

on the generator rotor aligns with the index mark

'

B

on the crankcase.

877-999-5686 between crankcase and cam drive sprocket.

NOTE:

Before installing the camshaft to the cylinder head, apply engine oil to the camshaft journals and cam faces.

EX.

IN.

ENGINE 3-73

3-74 ENGINE

Install the camshaft and camshaft sprocket.

Engage the hole of the sprocket

C

with the locating pin on the camshaft as shown.

Align the lines

D

on the camshaft so that they are parallel with the surface of the cylinder head.

NOTE:

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

* While aligning the lines

D

, remove chain slack by turning the sprocket counterclockwise lightly.

Install the C-ring

1

.

Install the lock washer as it covers the locating pin.

Apply THREAD LOCK SUPER to the bolts and tighten them to the specified torque.

*

99000-32030: THREAD LOCK SUPER 1303

"

Camshaft sprocket bolt: 11 N•m (1.1 kgf-m, 8.0 lb-ft)

2

Camshaft

3

Pin

4

Bolt

5

Lock washer

6

Camshaft sprocket

ENGINE 3-75

Turn the crankshaft until the TDC line

E

on the generator rotor aligns with the index mark

F

on the crankcase.

CYLINDER HEAD COVER

Clean the mating surface of the cylinder head and head cover before matching.

Install the dowel pins to the cylinder head.

Apply SUZUKI BOND to the periphery of the camshaft end cap

1

and fit it

1216

99000-31230: SUZUKI BOND 1216B

Apply SUZUKI BOND to the mating surface of the cylinder head cover.

1216

99000-31230: SUZUKI BOND 1216B

1216

"

Tighten the cylinder head cover bolts to the specified torque.

'

PartShark.com

Fit the washer to the bolt

A

.

877-999-5686

CAM CHAIN TENSION ADJUSTER

After removing the spring holder bolt and spring, unlock the ratchet mechanism

1

and push in the push rod

2

all the way.

NOTE:

Before installing the cam chain tension adjuster, unlock the ratchet mechanism

1

and move the push rod

2

in place to see if it slides smoothly.

1216

3-76 ENGINE

Install new gasket

3

and cam chain tension adjuster to the cylinder block and tighten its mounting bolts to the specified torque.

"

Cam chain tension adjuster bolt:

10 N•m (1.0 kgf-m, 7.0 lb-ft)

Install new O-ring

4

.

Install the spring and pin

5

.

Tighten the spring holder bolt

6

to the specified torque.

"

Cam chain tension adjuster spring holder bolt:

8 N•m (0.8 kgf-m, 6.0 lb-ft)

Adjust the valve clearance. (

!

2-5)

Tighten the valve timing inspection plug

7

and generator cover cap

8

to the specified torque.

"

Valve timing inspection plug:

23 N•m (2.3 kgf-m, 16.5 lb-ft)

Generator cover cap: 15 N•m (1.5 kgf-m, 11.0 lb-ft)

STARTER MOTOR

#

99000-25030: SUZUKI SUPER GREASE A (USA)

ing bolts to the specified torque.

877-999-5686

"

Starter motor mounting bolt: 10 N•m (1.0 kgf-m, 7.0 lb-ft)

SPARK PLUG

Tighten the spark plug to the specified torque. (

!

2-8)

"

Spark plug: 18 N•m (1.8 kgf-m, 13.0 lb-ft)

&

09930-10121: Spark plug wrench set

Mount the engine. (

!

3-8)

DRIVE TRAIN 4-1

DRIVE TRAIN

CONTENTS

REAR DRIVING SYSTEM ...............................................................................4- 2

REAR DRIVE REMOVAL .......................................................................4- 3

REAR DRIVE DISASSEMBLY ...............................................................4- 4

REAR DRIVE INSPECTION ...................................................................4- 9

REAR DRIVE REASSEMBLY ................................................................4-11

REAR DRIVE INSTALLATION ..............................................................4-16

SHIM ADJUSTMENT .............................................................................4-18

REASSEMBLY INFORMATION .............................................................4-21

2

4

6

4-2 DRIVE TRAIN

REAR DRIVING SYSTEM

1

Final gear case cover

2

Shim, LH

3

Bevel ring gear

4

Shim, RH

5

Final gear case

6

Shim

7

Bevel pinion gear

8

Pinion gear shaft coupling joint

9

Propeller shaft

0

Universal joint

FWD

REAR DRIVE REMOVAL

Remove the final gear case under cover

1

.

Drain gear oil. (

!

2-11)

Remove the rear wheels. (

!

7-11)

Remove the rear wheel hubs. (

!

7-11)

Remove the rear brake

2

. (

!

7-46)

Remove the axle housing set bolts/nuts.

Remove the final gear case together with the propeller shaft.

Remove the propeller shaft and spring

3

from the final gear case.

PartShark.com

Remove the axle housing/final gear case bolts.

DRIVE TRAIN 4-3

4-4 DRIVE TRAIN

Remove the rear axle together with the axle housing.

Remove the O-ring

4

.

REAR DRIVE DISASSEMBLY

FINAL GEAR CASE

Remove the final gear case cover bolts diagonally and evenly.

Pry the cover at the arrows as shown by tapping with a plastic mallet.

Remove the ring gear and shims.

Remove the dust seal with the special tool.

"

NOTE:

PartShark.com

necessary.

#

The removed dust seal must be replaced with a new one.

Remove the snap ring.

Remove the O-ring

1

.

Drive out the bearing from the other side with the special tool.

"

09913-70210: Bearing installer set

NOTE:

If there is no abnormal condition, the bearing removal is not necessary.

#

The removed bearing must be replaced with a new one.

Remove the bearing and oil seal with a suitable tool.

NOTE:

If there is no abnormal condition, the bearing/oil seal removal is not necessary.

#

The removed bearing and oil seal must be replaced with the new ones.

NOTE: essary.

#

The removed oil seal must be replaced with a new one.

DRIVE TRAIN 4-5

4-6 DRIVE TRAIN

Remove the bearing with the special tool.

"

09913-70210: Bearing installer set

NOTE:

If there is no abnormal condition, the bearing removal is not necessary.

#

The removed bearing must be replaced with a new one.

Remove the pinion gear shaft coupling joint with the special tools.

"

09923-74510: Bearing remover

09930-30104: Sliding shaft

Remove the oil seal with a suitable tool.

NOTE:

If there is no abnormal condition, the oil seal removal is not necessary.

#

The removed oil seal must be replaced with a new one.

Unstake the bearing locknut with a small chisel or drill.

877-999-5686

Remove the bearing locknut with the special tool.

"

09921-21820: Bearing locknut wrench

#

Replace the bearing locknut with a new one.

Remove the pinion gear assembly and shim.

Remove the stopper ring

1

and O-ring

2

.

Remove the bearing with a commercially available bearing puller or a hydraulic press.

NOTE:

If there is no abnormal condition, the bearing removal is not necessary.

#

The removed O-ring and bearing must be replaced with the new ones.

Remove the pinion gear pilot bearing with the special tools.

"

09930-30104: Sliding shaft

NOTE: essary.

#

PartShark.com

The removed bearing must be replaced with a new one.

DRIVE TRAIN 4-7

4-8 DRIVE TRAIN

UNIVERSAL JOINT

Remove the C-rings from the universal joint.

#

Replace the removed C-rings with new ones.

Remove the bearings by tapping with the special tool and a hammer.

"

09913-70210: Bearing installer set

Remove the universal joint.

REAR DRIVE INSPECTION

PROPELLER SHAFT

Inspect the splines of the propeller shaft for wear or damage.

Also, inspect the boot for cuts or damage.

If any defects are found, replace the propeller shaft and its boot with new ones.

UNIVERSAL JOINT

Inspect the universal joint and outer surface of the bearing for scuffing, wear and damage. If any defects are found, replace the bearings and universal joint as a set.

Insert the universal joint to the bearing and check the play by turning the universal joint, as shown. If excessive play is noted, replace the bearing with a new one.

FINAL GEAR CASE

wear or damage.

PartShark.com

with a new one.

OIL SEAL REMOVAL

!

4-4 to -6

DRIVE TRAIN 4-9

4-10 DRIVE TRAIN

Check the outer race play and smooth rotation of the bearing by hand while it is on the pinion gear shaft.

Inspect the pinion gear for wear or damage.

If the pinion gear is damaged, inspect the ring gear also.

If any defects are found, replace the bearing and gear with the new ones.

BEARING AND GEAR REMOVAL

!

4-7

Inspect the ring gear for wear or damage.

If the ring gear is damaged, inspect the pinion gear.

If any defects are found, replace the ring gear with a new one.

Check the gear case and case cover bearings for wear or damage.

If any wear or damage is found, replace the bearing with a new one.

BEARING REMOVAL

!

4-5 to -7

Check the breather rubber case for wear or damage. Also, check that the joint of the rubber case fits tightly.

REAR AXLE

Inspect the splines of the rear axle and splines of the ring gear for wear or damage.

If any wear or damage is found, replace the rear axle and ring gear with the new ones.

Check the axle shaft runout. (

!

7-61)

DRIVE TRAIN 4-11

REAR DRIVE REASSEMBLY

Reassemble the rear drive in the reverse order of disassembly.

Pay attention to the following points:

NOTE:

Before reassembly, thoroughly clean all parts in cleaning solvent.

FINAL GEAR CASE OIL SEAL

Install new oil seals into the gear case and case cover with the special tool.

Apply SUZUKI SUPER GREASE to the new oil seal lips.

"

$

877-999-5686

NOTE:

The marked side of the oil seal should be positioned outside.

(

!

4-21)

4-12 DRIVE TRAIN

FINAL GEAR CASE BEARING

Drive the bearings into the gear case and case cover with the special tool.

"

09913-70210: Bearing installer set

DUST SEAL

Fix the bearing race with the snap ring.

Apply SUZUKI SUPER GREASE to the bearing.

$

99000-25030: SUZUKI SUPER GREASE A ( USA)

99000-25010: SUZUKI SUPER GREASE A (Others)

PartShark.com

Install new dust seal with the special tool and then apply

SUZUKI SUPER GREASE to the seal lip.

"

09913-70210: Bearing installer set

$

99000-25030: SUZUKI SUPER GREASE A ( USA)

99000-25010: SUZUKI SUPER GREASE A (Others)

BEVEL PINION GEAR SHAFT BEARING

Drive the bearing onto the shaft with the special tool.

"

09913-70210: Bearing installer set

BEVEL PINION GEAR/SHIM/LOCKNUT

[FINAL ASSEMBLY]

Install new O-ring

1

onto the pinion gear shaft.

Install the shim, pinion gear assembly and new bearing locknut.

Tighten new bearing locknut to the specified torque.

"

09921-21820: Bearing locknut wrench

%

Bearing locknut: 100 N•m (10.0 kgf-m, 72.5 lb-ft)

NOTE:

After the backlash and tooth contact have been checked or adjusted (

!

4-18), stake the nut with a center punch.

DRIVE TRAIN 4-13

4-14 DRIVE TRAIN

BEVEL PINION GEAR SHAFT OIL SEAL

Install new stopper ring to pinion gear shaft securely.

Install new oil seal to the gear case with the special tool.

Apply SUZUKI SUPER GREASE to the new oil seal lip groove.

"

09913-85210: Bearing/oil seal installer

$

99000-25030: SUZUKI SUPER GREASE A ( USA)

99000-25010: SUZUKI SUPER GREASE A (Others)

NOTE:

After the backlash and tooth contact have been checked or adjusted, install the oil seal.

Apply SUZUKI SUPER GREASE to the splines of the pinion gear shaft and install the pinion gear shaft coupling joint by tapping with a plastic mallet.

$

99000-25030: SUZUKI SUPER GREASE A ( USA)

99000-25010: SUZUKI SUPER GREASE A (Others)

Apply 4 5 gram of WATER RESISTANCE GREASE to the outside of seal lip groove.

&

99000-25160: WATER RESISTANCE GREASE

Fit the removed shims install the ring gear

2

.

PartShark.com

FINAL GEAR CASE COVER/GEAR CASE

[FINAL ASSEMBLY]

Coat new O-ring with SUZUKI SUPER GREASE and apply

SUZUKI BOND to the mating surface of the cover, then install the gear case cover.

$

99000-25030: SUZUKI SUPER GREASE A ( USA)

99000-25010: SUZUKI SUPER GREASE A ( Others)

'

99104-31140: SUZUKI BOND 1207B (USA)

(

99000-31110: SUZUKI BOND 1215 (Others)

NOTE:

After the backlash and tooth contact have been checked or adjusted (

!

4-18), install new O-ring and apply SUZUKI

BOND.

Apply THREAD LOCK SUPER to the case cover bolts and tighten them to the specified torque in a crisscross pattern.

)

99000-32030: THREAD LOCK SUPER 1303

%

Gear case cover bolt: 26 N•m (2.6 kgf-m, 19.0 lb-ft)

NOTE:

After the backlash and tooth contact have been checked or adjusted, apply THREAD LOCK SUPER to the case cover bolts.

UNIVERSAL JOINT

Apply SUZUKI SUPER GREASE to the bearing and its dust seal lip.

$

99000-25030: SUZUKI SUPER GREASE A ( USA)

99000-25010: SUZUKI SUPER GREASE A ( Others)

PartShark.com

Install the universal joint and bearings with the special tool.

"

09913-70210: Bearing installer set

DRIVE TRAIN 4-15

4-16 DRIVE TRAIN

Install new C-rings by tapping with a copper hammer.

After reassembling the universal joint, check the joint movement smoothly. If a large resistance is felt to movement, tap the bearing with a plastic mallet lightly.

REAR DRIVE INSTALLATION

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

Coat new O-ring with SUZUKI SUPER GREASE and install it into the groove in the gear case.

$

99000-25030: SUZUKI SUPER GREASE A ( USA)

99000-25010: SUZUKI SUPER GREASE A (Others)

Apply SUZUKI SUPER GREASE to the splines of the axle.

$

PartShark.com

Apply THREAD LOCK SUPER to the axle housing/final gear case bolts, and tighten them to the specified torque.

)

99000-32030: THREAD LOCK SUPER 1303

%

Axle housing/final gear case bolt:

65 N•m (6.5 kgf-m, 47.0 lb-ft)

Install the spring into the rear end of the propeller shaft.

Apply SUZUKI SUPER GREASE to the splines of the propeller shaft.

$

99000-25030: SUZUKI SUPER GREASE A ( USA)

99000-25010: SUZUKI SUPER GREASE A ( Others)

DRIVE TRAIN 4-17

Tighten the axle housing set bolts/nuts

1

(RH) and

2

(LH) to the specified torque of each.

%

Axle housing set bolt/nut

1

(RH):

60 N•m (6.0 kgf-m, 43.5 lb-ft)

Axle housing set bolt/nut

2

(LH):

65 N•m (6.5 kgf-m, 47.0 lb-ft)

Pour the specified hypoid gear oil (SAE #90) in through the filler hole. (

!

PartShark.com

4-18 DRIVE TRAIN

SHIM ADJUSTMENT

BACKLASH

Install the pinion gear assembly, removed shim and new bearing locknut. (

!

4-13)

Tighten the bearing locknut to the specified torque.

(

!

4-13)

NOTE:

At this time, it is not necessary to stake the bearing locknut.

(

!

4-13)

Install the removed right side shim and ring gear. (

!

4-14)

Measure the backlash using the dial gauge, as shown. Take backlash readings at several places while turning the pinion gear shaft in each direction and securely holding the ring gear. If the backlash is not within specification, the shim must be changed and the backlash should be re-checked until correct. Refer to the chart at the right for the appropriate shim thickness.

*

Backlash

Standard: 0.05 0.30 mm (0.0020 0.0 118 in)

For right side of ring gear (

:

4-21)

NOTE:

Adjust the backlash by referring to the chart at the right and using the thickness of the removed shim as a guide.

Part No.

Shim thickness

1.26 mm (0.0496 in)

1.32 mm (0.0520 in)

Backlash Shim adjustment

1.38 mm (0.0543 in)

Under 0.05 mm

Increase shim thickness

27407-05820

1.44 mm (0.0567 in)

(0.0020 in)

(Shim set: 10 pcs)

1.50 mm (0.0591 in)

0.05 0.30 mm pieces of solder

A

Correct

1.56 mm (0.0614 in)

(0.0020 0 .0118 in)

1.62 mm (0.0638 in)

Over 0.30 mm

(0.0118 in)

Decrease shim thickness

PartShark.com

LEFT SIDE SHIM SELECTION

After the backlash has been checked or adjusted, put a few

1.68 mm (0.0661 in)

1.74 mm (0.0685 in)

1.80 mm (0.0709 in) gear back side, as shown.

877-999-5686

(O.D.: 1.4 2 .0 mm L: 6 mm) on the ring

NOTE:

* Do not install the left side shim at this time.

* Apply a small quantity of grease to the solders to prevent them from falling.

DRIVE TRAIN 4-19

Install the final gear case cover and tighten its bolts to the specified torque in a crisscross pattern. (

!

4-15)

NOTE:

* It is not necessary to install the O-ring to the final gear case cover at this time.

* Do not apply THREAD LOCK SUPER to the final gase cover bolts at this time.

%

Final gear case cover bolt: 26 N•m (2.6 kgf-m, 19.0 lb-ft)

Remove the final gear case cover. (

!

4-4)

Measure the thickness of compressed solder with the micrometer.

"

09900-20205: Micrometer

For left side of ring gear (

:

4-21)

Select the proper size of shim from the right chart, according as the compressed solder thickness.

After selecting the proper size of shim, install it on the ring gear back side.

Part No.

27407-05820

(Shim set: 10 pcs)

Shim thickness

1.26 mm (0.0496 in)

1.32 mm (0.0520 in)

1.38 mm (0.0543 in)

1.44 mm (0.0567 in)

1.50 mm (0.0591 in)

1.56 mm (0.0614 in)

1.62 mm (0.0638 in)

PartShark.com

1.68 mm (0.0661 in)

1.74 mm (0.0685 in)

1.80 mm (0.0709 in)

4-20 DRIVE TRAIN

TOOTH CONTACT

After backlash adjustment and left shim selection are carried out, the tooth contact must be checked. Pay attention to the following procedures:

Remove the ring gear.

Clean and degrease several teeth on the ring gear and pinion gear, and then apply a coating of machinist s layout dye or paste to several teeth of the pinion gear.

Install the ring gear with the shims in place.

Install the final gear case cover, and then tighten the bolts to the specified torque in a crisscross pattern. (

!

4-15)

%

Final gear case cover bolt: 26 N•m (2.6 kgf-m, 19.0 lb-ft)

NOTE:

At this time, it is not necessary to install the gear case cover s Oring.

Rotate the gear several turns in each direction. This will provide a contact pattern on the coated teeth of the gear.

Remove the ring gear and compare the coated teeth to the examples shown in

1

,

2

and

3

.

If tooth contact is found to be correct (example

2

), go to the FINAL ASSEMBLY sub-section on page 4-13 to -15 to complete installation.

If tooth contact is found to be incorrect (examples

1

and

3

), the shim between the pinion gear bearing and gear case must be changed and the tooth contact re-checked until correct.

Tooth contact

Contact at tooth top

1

Contact at tooth root

3

Shim adjustment

Decrease shim thickness

Increase shim thickness

Incorrect

(Contact at tooth top)

Correct

Incorrect

(Contact at tooth root)

#

For pinion gear (

:

4-21)

Make sure to check the backlash and shim thickness

Part No.

877-999-5686 tooth contact cannot be maintained when adjusting the backlash, replace the pinion gear and ring gear as

(Shim set: 6 pcs)

Shim thickness

1.38 mm (0.0543 in)

1.44 mm (0.0567 in)

1.50 mm (0.0591 in)

1.56 mm (0.0614 in)

1.62 mm (0.0638 in)

a set.

1.68 mm (0.0661 in)

REASSEMBLY INFORMATION

4 5 g ram

100 N.m

(10.0 kgf-m, 72.5 lb-ft)

DRIVE TRAIN 4-21

Pinion gear shim

Left side of ring gear shim

26 N•m

(2.6 kgf-m, 19.0 lb-ft)

Matching surfaces

Right side of ring gear shim

26 N•m

(2.6 kgf-m, 19.0 lb-ft)

4-22 DRIVE TRAIN

FUEL SYSTEM 5-1

FUEL SYSTEM

CONTENTS

FUEL TANK ...................................................................................................5- 2

CONSTRUCTION ....................................................................................5- 2

FUEL LINE INSPECTION .......................................................................5- 3

REMOVAL ...............................................................................................5- 3

REMOUNTING ........................................................................................5- 3

FUEL VALVE .................................................................................................5- 4

REMOVAL AND INSPECTION ...............................................................5- 4

FUEL STRAINER ....................................................................................5- 4

REMOUNTING ........................................................................................5- 4

CARBURETOR ..............................................................................................5- 5

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

SPECIFICATIONS...................................................................................5- 6

I.D. NO. LOCATION ................................................................................5- 6

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

DISASSEMBLY .......................................................................................5- 8

CLEANING ..............................................................................................5-12

INSPECTION ...........................................................................................5-12

REASSEMBLY ........................................................................................5-13

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

5

5-2 FUEL SYSTEM

FUEL TANK

CONSTRUCTION

1

Fuel tank

2

Fuel cap

3

Breather hose

4

Gasket

5

Seal washer

6

Fuel valve

7

Fuel hose

FUEL LINE INSPECTION

Inspect the fuel lines, fuel tank, fuel tank breather hoses and fuel tank cap for damage, clogging and leakage of fuel. If any damages are found, replace the defective parts with the new ones.

REMOVAL

Remove the front fender. (

!

7-6)

Turn the fuel valve to the ON position.

Disconnect the fuel hose

1

and vacuum hose

2

.

"

Gasoline is highly flammable and explosive. Keep heat, sparks and flames away from gasoline.

Remove the air cIeaner duct

3

.

Remove the fuel tank

4

.

Drain fuel completeIy.

REMOUNTING

Remount the fuel tank in the reverse order of removal.

FUEL SYSTEM 5-3

5-4 FUEL SYSTEM

FUEL VALVE

REMOVAL AND INSPECTION

Remove the fuel tank. (

!

5-3)

Drain fuel completely.

Remove the fuel valve.

"

Gasoline is highly flammable and explosive. Keep heat, sparks and flames away from gasoline.

FUEL STRAINER

If the fuel strainer is dirty with sediment or rust, fuel will not flow smoothly and loss in engine power may result. Clean the fuel strainer with compressed air.

REMOUNTING

Remount the fuel valve in the reverse order of removal.

"

Replace the removed gasket

1

and seal washers

2

with the new ones to prevent leakage of fuel.

CARBURETOR

CONSTRUCTION

1

Top cap

2

Spring

3

Holder

4

O-ring

5

Spring

6

Washer (t=0.5 mm, 0.02 in)

7

E-ring

8

Spacer

9

Washer (t=1.0 mm, 0.04 in)

0

Jet needle

A

Diaphragm

B

Ring

C

Piston valve

D

Vacuum hose

E

Air vent hose

F

Side cover

G

O-ring

H

Coasting enrichment valve

I

Coasting enrichment valve cover

J

Starter plunger

K

Pilot air jet

L

Pilot jet

M

Needle valve

N

Needle jet

O

O-ring

P

Starter jet

Q

Needle jet holder

R

Main jet ring

S

Main jet

T

Float

U

O-ring

V

Washer

W

Spring

X

Pilot screw

Y

Throttle stop screw

Z

O-ring

[

Float chamber

PartShark.com

FUEL SYSTEM 5-5

5-6 FUEL SYSTEM

SPECIFICATIONS

ITEM

Carburetor type

Bore size

I.D. No.

Idle r/min

Float height

Main jet

Jet needle

Needle jet

Pilot jet

Pilot screw

Throttle cable play

(M.J.)

(J.N.)

(N.J.)

(P.J.)

(P.S.)

Starter (enricher) plunger cable play

E-19: EU E-28: Canada

E-19, 28

MIKUNI BSR29

29.0 mm

(1.14 in)

21G0

1 500 – 100 r/min

13.0 – 1.0 mm

(0.51 – 0.04 in)

#125

SPECIFICATION

5DH54-2nd

P-0M

#20

1-1/2 turns back

3 5 mm

(0.12 0.20 in)

0.5 1 .0 mm

(0.02 0.04 in)

E-33: USA (California)

E-33

←

←

21G1

←

←

#

←

#

#

PRE-SET

←

←

I.D. NO. LOCATION

Carburetor has an I.D. number

1

printed on its body.

REMOVAL

Remove the seat. (

!

7-5)

Disconnect the air vent hose

1

.

Disconnect the fuel hose

2

and vacuum hose

3

.

Disconnect the starter cable

4

.

Loosen the carburetor clamp screws.

Pull out the carburetor from between the engine and air cleaner.

Remove the carburetor side cover

5

.

877-999-5686

Remove the O-ring

6

.

Disconnect the throttle cable

7

.

Remove the carburetor.

FUEL SYSTEM 5-7

5-8 FUEL SYSTEM

DISASSEMBLY

Remove the fuel hose

1

, overflow hose

2

, vacuum hose

3 and air vent hose

4

.

Remove the throttle stop screw

5

.

Remove the carburetor top cap.

#

Do not use compressed air on the carburetor body before removing the diaphragm; this may damage the diaphragm.

Remove the spring and diaphragm assembly

6

.

PartShark.com

Remove the jet needle holder.

Remove the following parts.

7

Jet needle holder

8

O-ring

9

Spring

0

Washer (t=0.5 mm, 0.02 in)

A

Jet needle

B

Washer (t=1.0 mm, 0.04 in)

Remove the diaphragm by removing the ring

C

.

Remove the coasting enrichment valve cover

D

and spring.

Remove the coasting enrichment valve

E

.

PartShark.com

Remove the pilot air jet

F

.

FUEL SYSTEM 5-9

5-10 FUEL SYSTEM

Remove the float chamber.

Remove the O-ring

G

.

#

Replace the removed O-ring with a new one to prevent leakage of fuel.

Remove the float pin

H

, float

I

and needle valve

J

.

Remove the valve seat

K

.

877-999-5686

Remove the following parts.

L

Main jet, main jet ring, needle jet holder and needle jet

M

Pilot screw

N

Starter jet

O

Pilot jet

NOTE:

Before removing the pilot screw

M

, its setting must be determined. Slowly turn the pilot screw clockwise and count the number of turns until it is lightly seated. Make a note of how many turns were made.

When reassembling the pilot screw, you will want to set it to its original position.

#

Do not use wire to clean the passageways, valve seat and jets. Use compressed air only.

PILOT SCREW REMOVAL (FOR E-33)

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 4 mm (0.16 in) 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 many turns were made so the screw can be reset correctly after cleaning.

ring.

PartShark.com

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

FUEL SYSTEM 5-11

5-12 FUEL SYSTEM

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. If necessary, soak each circuit in a dip-type cleaning solution to loosen dirt and varnish.

Dry the carburetor body using compressed air.

#

Do not use a wire to clean the jets or passageways. If wire is used, the jets and passageways may become damaged. If the components cannot be cleaned with a spray-type cleaner it may be necessary to soak the components in a dip-type cleaning solution. Always follow the chemical manufacturer s instructions for proper use and cleaning of the carburetor components.

After cleaning, reassemble the carburetor.

#

Replace the removed O-rings with new ones.

INSPECTION

* Pilot jet

877-999-5686

* Piston valve

* Starter jet * Main jet

* Pilot screw

* Pilot air jet

* Needle jet holder

* Float

* Needle valve

* Valve seat

* Jet needle

* Needle jet

* O-rings

* Throttle valve

* Diaphragms

* Pilot outlet and by-pass ports

* Vacuum hose

* Air vent hose

* Overflow hose

* Fuel hose

NEEDLE VALVE INSPECTION

If foreign matter is caught between the valve seat and the needle valve, the gasoline will continue flowing and overflow. If the valve seat and needle valve are worn beyond the permissible limits, similar trouble will occur. Conversely, if the needle valve sticks, the gasoline will not flow into the float chamber. Clean the float chamber and float parts with gasoline. If the needle valve is worn as shown, replace and the valve seat with a new one.

Clean the fuel passage of the mixing chamber using compressed air.

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.

Bend the tongue as necessary to bring the float height

A

to the specified level.

$

Float height

A

: 13.0 – 1.0 mm (0.51 – 0.04 in)

%

09900-20101: Venier calipers

REASSEMBLY

Reassemble the carburetor in the reverse order of disassembly.

Pay attention to the following points:

PILOT SCREW

After cleaning, install the pilot screw

1

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.

1

Pilot screw

2

#

PartShark.com

NEEDLE JET

Install the needle jet with its smaller internal diameter portion facing to the needle jet holder.

FUEL SYSTEM 5-13

5-14 FUEL SYSTEM

VALVE SEAT

Install the valve seat

1

into the carburetor body, and then tighten the screw

2

.

NOTE:

Make sure that the collar of the screw

2

holds the step of the valve seat

1

securely.

DIAPHRAGM

Install the diaphragm to the piston valve with the lug on the diaphragm aligned with the cutout on the piston valve.

Install the ring

1

to the piston valve.

Install the diaphragm assembly.

NOTE:

When installing the diaphragm, make sure the tab of the diaphragm is aligned with the concave section of the carburetor body s rim.

THROTTLE STOP SCREW

stop screw, then install the throttle stop screw to the carburetor.

&

PartShark.com

FUEL SYSTEM 5-15

REMOUNTING

Remount the carburetor assembly in the reverse order of removal. Pay attention to the following points:

Fit the lug on the carburetor with the intake pipe s projection.

Position the carburetor clamps as shown in the illustration.

Connect the carburetor hoses properly. (

!

9-16)

Left Right Left

45ß

Right

After the carburetor assembly has been remounted onto the engine, perform the following adjustments:

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

!

2-9

* Engine idle speed .........................................

!

2-9

Engine side

Air cleaner side

 

LUBRICATION SYSTEM

LUBRICATION SYSTEM 6-1

CONTENTS

LUBRICATION SYSTEM ...............................................................................6- 2

ENGINE LUBRICATION CIRCUIT .........................................................6- 2

ENGINE LUBRICATION FLOW CHART ...............................................6- 4

OIL PRESSURE .............................................................................................6- 5

OIL FILTER ....................................................................................................6- 5

OIL STRAINER ..............................................................................................6- 5

OIL PUMP ......................................................................................................6- 5

6

6-2 LUBRICATION SYSTEM

LUBRICATION SYSTEM

ENGINE LUBRICATION CIRCUIT

OIL PUMP

OIL FILTER

LUBRICATION OIL

RETURNED OIL

LUBRICATION SYSTEM 6-3

EXHAUST SIDE

INTAKE SIDE

LUBRICATION OIL

RETURNED OIL

6-4 LUBRICATION SYSTEM

ENGINE LUBRICATION FLOW CHART

OIL PRESSURE

(

!

2-25)

OIL FILTER

(

!

2-10)

OIL STRAINER

(

!

3-20, -61 and -62)

OIL PUMP

(

!

3-18 and -64)

LUBRICATION SYSTEM 6-5

 

CHASSIS

CONTENTS

EXTERIOR PARTS ........................................................................................7- 3

CONSTRUCTION ....................................................................................7- 3

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

REMOUNTING ........................................................................................7- 8

FRONT AND REAR WHEELS.......................................................................7-10

CONSTRUCTION ....................................................................................7-10

REMOVAL ...............................................................................................7-11

INSPECTION AND DISASSEMBLY .......................................................7-12

REASSEMBLY AND REMOUNTING......................................................7-13

TIRES .............................................................................................................7-16

TIRE REPLACEMENT ............................................................................7-16

FRONT BRAKE .............................................................................................7-18

CONSTRUCTION ....................................................................................7-18

BRAKE PAD REPLACEMENT ...............................................................7-19

BRAKE FLUID REPLACEMENT ............................................................7-19

BRAKE CALIPER REMOVAL AND DISASSEMBLY.............................7-20

BRAKE CALIPER INSPECTION ............................................................7-21

BRAKE CALIPER REASSEMBLY AND REMOUNTING .......................7-23

BRAKE DISC REMOVAL AND DISASSEMBLY ....................................7-24

BRAKE DISC INSPECTION....................................................................7-25

BRAKE DISC REASSEMBLY AND REMOUNTING ..............................7-25

MASTER CYLINDER REMOVAL AND DISASSEMBLY........................7-26

MASTER CYLINDER INSPECTION .......................................................7-27

MASTER CYLINDER REASSEMBLY AND REMOUNTING ..................7-27

PartShark.com

INSPECTION ...........................................................................................7-31

SUSPENSION SETTING .........................................................................7-34

STEERING .....................................................................................................7-35

CONSTRUCTION ....................................................................................7-35

REMOVAL ...............................................................................................7-36

INSPECTION AND DISASSEMBLY .......................................................7-38

REASSEMBLY AND REMOUNTING......................................................7-40

TOE-IN ADJUSTMENT ...........................................................................7-43

FRONT WHEEL, FRONT BRAKE, FRONT SUSPENSION AND

STEERING REASSEMBLING INFORMATION.............................................7-44

CHASSIS 7-1

7

7-2 CHASSIS

CHASSIS

CONTENTS

REAR BRAKE ............................................................................................... 7-45

CONSTRUCTION ................................................................................... 7-45

REMOVAL AND DISASSEMBLY........................................................... 7-46

INSPECTION .......................................................................................... 7-48

REASSEMBLY AND REMOUNTING ..................................................... 7-49

REAR SHOCK ABSORBER ......................................................................... 7-53

CONSTRUCTION ................................................................................... 7-53

REMOVAL .............................................................................................. 7-53

INSPECTION .......................................................................................... 7-53

REASSEMBLY ....................................................................................... 7-54

REMOUNTING ........................................................................................ 7-54

SUSPENSION SETTING ........................................................................ 7-55

REAR SHOCK ABSORBER DISPOSAL ............................................... 7-55

REAR SUSPENSION .................................................................................... 7-56

CONSTRUCTION ................................................................................... 7-56

REMOVAL .............................................................................................. 7-57

INSPECTION AND DISASSEMBLY....................................................... 7-57

REASSEMBLY ....................................................................................... 7-58

REMOUNTING ........................................................................................ 7-59

REAR AXLE .................................................................................................. 7-60

CONSTRUCTION ................................................................................... 7-60

REMOVAL .............................................................................................. 7-61

INSPECTION .......................................................................................... 7-61

REASSEMBLY AND REMOUNTING ..................................................... 7-62

PartShark.com

REMOVAL .............................................................................................. 7-64

EXTERIOR PARTS

CONSTRUCTION

CHASSIS 7-3

1

Front fender

2

Fuel tank top cover

3

Fuel tank side cover

4

Front fender bracket

5

Headlight case

7-4 CHASSIS

1

Rear fender

2

Rear fender cover

3

Footrest mud guard

REMOVAL

SEAT

Remove the seat by pulling the lever.

FRONT GRIP BAR

Remove the front grip bar

1

.

REAR GRIP BAR

Remove the rear grip bar

1

.

FUEL TANK SIDE COVER

PartShark.com

CHASSIS 7-5

7-6 CHASSIS

FRONT FENDER

Remove the fuel tank side covers. (

!

7-5)

Remove the screws and fasteners.

Open the fuel tank cap and remove the fuel tank top cover

1

.

Remove the reverse lock release knob

2

.

Remove the screws that connect the front fender with the head light.

877-999-5686

FOOTREST MUD GUARD

Remove the fuel tank side covers. (

!

7-5)

Remove the footrest mud guards

1

and

2

.

FOOTREST

Remove the footrest mud guards. (

!

Above)

Remove the footrest

1

and

2

.

REAR FENDER

Remove the fuel tank side covers. (

!

7-5)

Remove the battery holder

1

and battery.

CHASSIS 7-7

7-8 CHASSIS

Remove the screws.

Pull out the taillight assembly

2

with the bracket.

Remove the rear fender mounting bolts.

Remove the footrest mud guards.

Remove the rear fender.

REMOUNTING

Remount the exterior parts in the reverse order of removal. Pay attention to the following points:

FRONT GRIP BAR

torque.

877-999-5686

"

Front grip bar mounting bolt:

26 N•m (2.6 kgf-m, 19.0 lb-ft)

REAR GRIP BAR

Tighten the rear grip bar mounting bolts to the specified torque of each.

"

Rear grip bar mounting bolt

1

:

28 N•m (2.8 kgf-m, 20.5 lb-ft)

2

:

55 N•m (5.5 kgf-m, 40.0 lb-ft)

FOOTREST

Apply THREAD LOCK to the bolts

A

and tighten each bolt to the specified torque.

#

99000-32050: THREAD LOCK 1342

"

Footrest mounting bolt

A

: 55 N•m (5.5 kgf-m, 40.0 lb-ft)

Footrest mounting bolt

B

: 26 N•m (2.6 kgf-m, 19.0 lb-ft)

CHASSIS 7-9

7-10 CHASSIS

FRONT AND REAR WHEELS

CONSTRUCTION

1

Front brake disc

2

Spacer

3

Dust seal

4

Bearing

5

Spacer

6

Front wheel Hub

7

Rear wheel Hub

8

Hub plate

9

Disc cover

@

ITEM

A

B

C

D

N•m kgf-m

23 2.3

50

65

5.0

6.5

138 13.8

lb-ft

16.5

36.0

47.0

99.9

REMOVAL

FRONT AND REAR WHEELS

Place the vehicle on the level ground.

Support the vehicle with a jack or wooden block.

Remove the wheel.

FRONT WHEEL HUB

Remove the front wheel. (

!

Above)

Remove the front hub plate

1

.

Remove the cotter pin and loosen the wheel hub nut with applying the front brake.

Remove the wheel hub nut and washer.

Remove the front brake caliper. (

!

7-20)

Remove the front wheel hub

2

.

$

Do not operate the front brake lever while the caliper is removed.

Remove the spacer

3

.

Remove the brake disc. (

!

7-24)

Remove the rear wheel. (

!

Remove the rear hub plate

1

877-999-5686

Remove the cotter pin and loosen the wheel hub nut with applying the rear brake.

Remove the wheel hub nut and washer.

Remove the wheel hub

2

.

CHASSIS 7-11

7-12 CHASSIS

INSPECTION AND DISASSEMBLY

DUST SEAL

Inspect the dust seal lips for wear or damage.

If any damages are found, replace the dust seal with a new one.

Remove the dust seals with the special tool.

%

09913-50121: Oil seal remover

$

Replace the removed dust seals with new ones.

HUB BEARINGS

Inspect the inner race play of the hub bearing by hand while it is in the wheel hub.

Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. If there is anything unusual, replace the bearing with a new one.

Remove the hub bearings with the special tool.

%

$

PartShark.com

REASSEMBLY AND REMOUNTING

FRONT WHEEL HUB

Apply SUZUKI SUPER GREASE to the hub bearings and the lips of the dust seals before installing them.

&

99000-25030: SUZUKI SUPER GREASE A ( USA)

99000-25010: SUZUKI SUPER GREASE A ( Others)

Install the hub bearings and spacer into the front wheel hub.

%

09913-70210: Bearing installer set

09924-84510: Bearing installer set

NOTE:

Install the inner bearing

1

and the spacer

2

first, and then install the outer bearing

3

. Make sure the sealed side of the bearing faces the bearing installer.

CHASSIS 7-13

Install the dust seals into the front wheel hub with stamped

%

877-999-5686

Apply SUZUKI SUPER GREASE to the dust seal lips.

&

99000-25030: SUZUKI SUPER GREASE A ( USA)

99000-25010: SUZUKI SUPER GREASE A (Others)

Install the brake disc. (

!

7-25)

7-14 CHASSIS

Install the spacer

4

to the front wheel hub.

Install the front wheel hub to the front axle

5

.

Install the front brake caliper. (

!

7-24)

Tighten the front wheel hub nut to the specified torque.

"

Front wheel hub nut: 65 N•m (6.5 kgf-m, 47.0 lb-ft)

Install the cotter pin into the front axle as shown.

Install the front hub plate.

Install the front wheel. (

!

7-15)

$

Replace the removed cotter pin with a new one.

REAR WHEEL HUB

rear wheel hub s spline.

&

877-999-5686

Apply detergent to the O-ring

1

and install it to the right rear wheel hub.

NOTE:

Check the O-ring before installing. If abnormal, change the O-ring with a new one.

$

Do not apply grease to the right rear wheel hub s spline.

Install the rear wheel hub and washer.

NOTE:

The convex side of the washer faces outside.

INSIDE

OUTSIDE

Washer

Tighten the rear wheel hub nut to the specified torque.

"

Rear wheel hub nut: 138 N•m (13.8 kgf-m, 99.9 lb-ft)

Install the cotter pin into the rear axle as shown.

Install the rear hub plate. (RH only)

Install the rear wheel. (

!

Below)

$

Replace the removed cotter pin with a new one.

FRONT WHEEL

Tighten the front wheel set nuts to the specified torque.

"

Front wheel set nut: 50 N•m (5.0 kgf-m, 36.0 lb-ft)

NOTE:

When installing the front wheel, make sure that the arrow

A

on the tire points in the direction of rotation.

REAR WHEEL

"

NOTE:

PartShark.com

SIDE FACING OUTWARDS

B

on the rear tire faces outwards.

CHASSIS 7-15

7-16 CHASSIS

TIRES

TIRE REPLACEMENT

Remove the front and rear wheels. (

!

7-11)

After removing the air valve cap, release the tire pressure by depressing the valve.

Dismount the bead from the rim completely as shown.

Separate the tire from the rim by using a set of tire levers and rim protectors.

$

When using the tire lever, do not scratch or hit the sealing portion (hump) of the wheel or it may cause air-leakage.

Apply tire lubricant to the tire bead and the flange of the rim.

$

Never apply grease, oil or gasoline to the tire bead because they will deteriorate the tire.

$

✩✩

PartShark.com

for the front and AT20

×

10-9

✩

for the rear.

The use of tires other than the standard may cause instability. It is highly recommended to use the specified tire.

Mount the tire on the rim.

NOTE:

Inspect the sealing portion of the rim for contamination and distortion before installing the tire on the rim.

When installing each tire, make sure the arrow

A

on the tire points in the direction of rotation. Also, make sure the outer side of the wheel rim is facing outward.

NOTE:

For inspecting the tire refer to page 2-17.

Inspect the valve core, before installation.

Inflate the tire to seat the tire bead.

'

Maximum tire bead seat pressure

Front and rear: 250 kPa (2.5 kgf/cm

2

, 36 psi)

$

Place the tire under a protective tire cage or similar protective covering device before inflating the tire. To minimize the possibility of tire damage when seating the tire bead, never exceed the MAXIMUM TIRE BEAD

SEAT PRESSURE rating shown on the tire.

NOTE:

Check the rim line

1

cast on the tire side walls. It must be

equidistant from the wheel rim all the way around. If the distance between the rim line and the wheel rim varies this indicates that the bead is not properly seated. If this is so, deflate the tire completely, and unseat the tire bead on both sides. Then, coat the bead with clean water, and re-seat the tire.

Adjust the tire pressure to specification. (

!

2-18)

$

ATING PRESSURE rating of the tire. This is indicated by a

✩

following the tire size shown on the sidewall.

The number of

✩

on the tire indicates the maximum operating pressure.

877-999-5686

'

Maximum operating pressure

✩

: 25 kPa (0.25 kgf/cm

2

, 3.6 psi)

✩✩

: 35 kPa (0.35 kgf/cm

2

, 5.1 psi)

✩✩✩

: 45 kPa (0.45 kgf/cm

2

, 6.5 psi)

CHASSIS 7-17

7-18 CHASSIS

FRONT BRAKE

CONSTRUCTION

@

ITEM

A

G

H

I

B

C

D

E

F

N•m kgf-m

10 1.0

23

6

26

18

18

2.3

0.6

2.6

1.8

1.8

23

23

16

2.3

2.3

1.6

lb-ft

7.0

16.5

4.4

19.0

13.0

13.0

16.5

16.5

11.6

A

Master cylinder mounting bolt

B

Brake hose union bolt

C

Air bleeder valve

D

Brake caliper mounting bolt

E

Brake pad mounting pin

F

Caliper holder pin

G

Caliper holder slide pin

H

Brake disc bolt

I

Brake pipe nut

1

Master cylinder reservior cap

2

Diaphragm

3

Master cylinder clamp

4

Boot

5

Piston/cup set

6

Cup

7

Spring

8

Master cylinder

9

Brake hose No. 1

0

Piston

A

Piston seal

B

Dust seal

C

Brake caliper

D

Brake caliper holder

E

Brake pad

F

Pad spring

G

Disc cover

H

Front brake disc

I

Brake pipe

J

Brake hose No. 2

13

(

PartShark.com

* This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix different types of fluid, such as silicone-based or petroleum-based brake fluids.

* Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or which has been stored for a long periods of time.

* When storing brake fluid, seal the container completely and keep it away from children.

* When replenishing brake fluid, take care not to get dust into the fluid.

* When washing brake components, use new brake fluid. Never use cleaning solvent.

* A contaminated brake disc or brake pad reduces braking performance. Discard contaminated pads and clean the brake disc with high quality brake cleaner or a neutral detergent.

$

Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials etc. and will damage them severely.

BRAKE PAD REPLACEMENT

Remove the front wheel. (

!

7-11)

Remove the brake caliper mounting bolts

1

and brake pad mounting pins

2

.

Remove the brake pads.

$

* Do not operate the brake lever during or after brake pad removal.

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

Install the new brake pads.

NOTE:

The shim must be installed to the caliper piston side pad.

Tighten the brake pad mounting pins

3

and brake caliper mounting bolts

4

to the specified torque.

"

Brake pad mounting pin: 18 N•m (1.8 kgf-m, 13.0 lb-ft)

Brake caliper mounting bolt:

26 N•m (2.6 kgf-m, 19.0 lb-ft)

NOTE:

After replacing the brake pads, pump the brake lever a few times to check for proper brake operation and then check the brake fluid level.

PartShark.com

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

CHASSIS 7-19

7-20 CHASSIS

Connect a clear hose 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 end of the inspection window.

"

Brake air bleeder valve: 6.0 N•m (0.6 kgf-m, 4.4 lb-ft)

$

* Never reuse the brake fluid left over from previous servicing and which has been stored for long periods of time.

* Bleed air from the brake system.

(

!

2-16)

BRAKE CALIPER REMOVAL AND

DISASSEMBLY

Remove the front wheel. (

!

7-11)

Disconnect the brake hose from the brake caliper by removing the brake hose union bolt

1

and allow the brake fluid to drain into a suitable receptacle.

Remove the brake caliper by removing the brake caliper mounting bolts

2

.

Remove the brake pads. (

!

7-19)

(

and discolor painted surfaces. Check the brake hose,

Remove the spring

3

.

877-999-5686

Place a rag over the brake caliper piston to prevent the piston from popping out and then force out the piston using compressed air.

$

Do not use high pressure air to prevent brake caliper piston damage.

Remove the dust seal and piston seal.

$

Do not reuse the dust seal and piston seal to prevent fluid leakage.

Remove the cap

4

and loosen the brake caliper holder slide pin

5

.

Remove the brake caliper holder

6

.

Remove the brake caliper holder slide pin

7

.

PartShark.com

BRAKE CALIPER INSPECTION

BRAKE CALIPER

Inspect the brake caliper cylinder wall for nicks, scratches or other damage. If any damages are found, replace the brake caliper with a new one.

CHASSIS 7-21

7-22 CHASSIS

BRAKE CALIPER PISTON

Inspect the brake caliper piston for any scratches or other damage. If any damages are found, replace the piston with a new one.

RUBBER PARTS

Inspect the rubber parts for damage. If any damages are found, replace them with new ones.

CALIPER HOLDER

Inspect the caliper holder

1

and pin

2

for damage. If any damages are found, replace them with new ones.

BRAKE CALIPER REASSEMBLY AND

REMOUNTING

Reassemble and remount the brake caliper in the reverse order of removal and disassembly. Pay attention to the following points:

Wash the caliper bore and piston with the specified brake fluid. Thoroughly wash the dust seal grooves and piston seal grooves.

)

Specification and classification: DOT 4

$

* Wash the brake caliper components with new brake fluid before reassembly.

* Do not wipe the brake fluid off with a rag 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.

* Replace the removed piston seals and dust seals with new ones.

* Apply brake fluid to all of the seals, brake caliper bores and pistons before reassembly.

PISTON SEAL

Install the piston seal

1

and dust seal

2

as shown.

Tighten the pin

2

877-999-5686

torque.

PartShark.com

BRAKE CALIPER HOLDER

"

Caliper holder pin: 18 N•m (1.8 kgf-m, 13.0 lb-ft)

Apply SUZUKI SILICONE GREASE to the brake caliper holder pin

2

.

*

99000-25100: SUZUKI SILICONE GREASE

CHASSIS 7-23

7-24 CHASSIS

Apply SUZUKI SILICONE GREASE to the brake caliper holder slide pin.

*

99000-25100: SUZUKI SILICONE GREASE

Install the pin

1

, washer

2

and caliper holder

3

to the caliper.

Apply THREAD LOCK SUPER to the pin

1

.

+

99000-32130: THREAD LOCK SUPER 1360

Tighten the pin

1

to the specified torque.

"

Caliper holder slide pin: 23 N•m (2.3 kgf-m, 16.5 lb-ft)

Install the pads and spring to the caliper.

Tighten the brake pad mounting pins

4

, brake caliper mounting bolts

5

and brake hose union bolt

6

to the specified torque.

"

Brake pad mounting pin: 18 N•m (1.8 kgf-m, 13.0 lb-ft)

Brake caliper mounting bolt:

26 N•m (2.6 kgf-m, 19.0 lb-ft)

Brake hose union bolt: 23 N•m (2.3 kgf-m, 16.5 lb-ft)

NOTE:

Before remounting the brake caliper, push the brake caliper pistons all the way into the caliper.

$

brake caliper. (

!

PartShark.com

2-16)

BRAKE DISC REMOVAL AND

DISASSEMBLY

Remove the front wheel hub. (

!

7-11)

Remove the brake disc.

BRAKE DISC INSPECTION

Remove the front wheel. (

!

7-10)

Remove the caliper. (

!

7-19)

Inspect the brake disc for cracks or damage and measure the thickness using the micrometer. If any damages are found or if the thickness is less than the service limit, replace the brake disc with a new one.

%

09900-20205: Micrometer (0 25 mm)

'

Brake disc thickness

Service Limit: 2.5 mm (0.098 in)

Measure the runout using the dial gauge. If the runout exceeds the service limit, replace the brake disc with a new one.

%

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

09900-20701: Magnetic stand

'

Brake disc runout

Service Limit: 0.3 mm (0.012 in)

If either measurement exceeds the service limit, replace the brake disc with a new one.

BRAKE DISC REASSEMBLY AND

REMOUNTING

Reassemble and remount the brake disc in the reverse order of removal and disassembly. Pay attention to the following points:

Install the disc to the wheel hub with the punching letters

A on the disc showed up.

NOTE:

Make sure that the disc is clean and free of any greasy matter.

tighten them to the specified torque.

+

PartShark.com

"

Brake disc bolt: 23 N•m (2.3 kgf-m, 16.5 lb-ft)

Install the front wheel hub. (

!

7-14)

Install the front wheel. (

!

7-15)

CHASSIS 7-25

7-26 CHASSIS

MASTER CYLINDER REMOVAL AND

DISASSEMBLY

Place a rag underneath the brake hose union bolt on the master cylinder to catch any split brake fluid. Remove the brake hose union bolt and disconnect the brake hose.

$

Immediately wipe off any brake fluid contacting any part of the vehicle. The brake fluid reacts chemically with paint, plastics, rubber materials, etc., and will damage them severely.

Remove the master cylinder assembly.

Disconnect the brake switch coupler.

Remove the brake lever

1

and brake switch

2

.

Remove the reservoir cap

3

and diaphragm

4 from the master cylinder.

Drain the brake fluid.

877-999-5686

Pull the dust boot

5

out and remove the snap ring

6

.

Remove the piston/secondary cup, primary cup and spring.

7

Secondary cup

8

Piston

9

Primary cup

0

Spring

MASTER CYLINDER INSPECTION

MASTER CYLINDER

Inspect the master cylinder bore for any scratches or damage. If any damages are found, replace the master cylinder with a new one.

PISTON AND RUBBER PARTS

Inspect the piston surface, primary cup, secondary cup and dust boot for any scratches, wear or damage. If any damages are found, replace them with a new one.

MASTER CYLINDER REASSEMBLY AND

Reassemble and remount the master cylinder in the reverse points:

$

PartShark.com

* Wash the master cylinder components with new brake fluid before reassembly.

* Do not wipe the brake fluid off with a rag 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 the component to be inserted to the bore.

)

Specification and classification: DOT 4

CHASSIS 7-27

7-28 CHASSIS

Align the master cylinder holder s mating surface

1

with the punched mark

2

on the handlebars and tighten the upper clamp bolt first.

"

Master cylinder clamp bolt: 10 N•m (1.0 kgf-m, 7.0 lb-ft)

A

Master cylinder

B

Master cylinder upper clamp bolt

C

Handlebar

D

Clearance

Tighten the brake hose union bolt

3

to the specified torque.

"

Brake hose union bolt: 23 N•m (2.3 kgf-m, 16.5 lb-ft)

NOTE:

After the brake hose union touching to the stopper, tighten the union bolt.

$

Bleed air from the brake system after reassembling the master cylinder. (

!

2-16)

FRONT SUSPENSION

CONSTRUCTION

CHASSIS 7-29

1

Front shock absorber

2

Upper wishbone arm

3

Bushing

4

Lower wishbone arm

5

Steering knuckle

6

Snap ring

7

Knuckle end

A

Shock absorber mounting upper nut

B

Shock absorber mounting lower nut

C

Wishbone arm pivot nut

D

Steering knuckle nut

E

Tie rod end nut

@

ITEM

AB

C

DE

N•m kgf.m

60 6.0

65

29

6.5

2.9

lb-ft

43.5

47.0

21.0

7-30 CHASSIS

REMOVAL AND DISASSEMBLY

Remove the wheel hub. (

!

7-11)

Remove the brake hose clamp

1

.

Disconnect the brake hose from the brake hose clamp

2

.

Remove the front disc cover

3

.

Remove the cotter pin, tie rod end nut and washer.

Disconnect the tie rod end with a commercially available ball bearing joint remover

4

.

877-999-5686

Remove the shock absorber lower mounting bolt

5

.

Remove the wishbone arm assembly

6

.

Remove the front shock absorber

7

.

Remove the cotter pins, knuckle nuts and washers.

Disconnect the steering knuckle

8

with a commercially available ball bearing joint remover.

INSPECTION

Inspect the shock absorber for oil leakage or damage. If any one.

877-999-5686

Inspect the rubber bushing for wear or damage.

If any damages are found, replace the shock absorber with a new one.

CHASSIS 7-31

7-32 CHASSIS

KNUCKLE

Inspect the knuckle for damage. If any damages are found, replace the knuckle with a new one.

KNUCKLE END

Inspect the knuckle end boots for wear or damage. If any damages are found, replace the wishbone arm with a new one.

WISHBONE ARM

Inspect the wishbone arms for wear or damage. If any damages are found, replace the wishbone arm with a new one.

Inspect the rubber bushing for wear or damage. If any damages

877-999-5686

BRAKE DISC COVER

Inspect the brake disc cover for damage. If any damages are found, replace the brake disc cover with a new one.

REASSEMBLY AND REMOUNTING

Reassemble and remount the front suspension in the reverse order of removal and disassembly. Pay attention to the following points:

Degrease the tapered portions of the knuckle, knuckle end and tie rod end with nonflammable cleaning solvent.

CHASSIS 7-33

Install the wishbone arms to the knuckle.

Install the washers and tighten the knuckle nuts to the specified torque.

"

Knuckle nut: 29 N•m (2.9 kgf-m, 21.0 lb-ft)

Install new cotter pins.

$

877-999-5686

Install the front shock absorber

1

.

7-34 CHASSIS

Apply THREAD LOCK SUPER to the wishbone arm pivot bolts

3

.

Tghten the upper and lower front shock absorber mounting nuts

2

and the wishbone arm pivot nuts

3

to the specified torque.

,

99000-32030: THREAD LOCK SUPER 1303 (USA)

-

99000-32110: THREAD LOCK SUPER 1322 (Others)

"

Wishbone arm pivot nut: 65 N•m (6.5 kgf-m, 47.0 lb-ft)

Shock absorber upper mounting nut:

60 N•m (6.0 kgf-m, 43.5 lb-ft)

Install the washer and tighten the tie rod end nut to the specified torque.

"

Tie rod end nut: 29 N•m (2.9 kgf-m, 21 lb-ft)

Install new cotter pin.

$

Replace the removed cotter pin with a new one.

Apply THREAD LOCK SUPER to the disc cover mounting bolts, and then tighten the bolts.

+

99000-32130: THREAD LOCK SUPER 1360

SPRING PRE-LOAD ADJUSTMENT

877-999-5686

Position 5 provides the stiffest spring pre-load.

STD POSITION: 2

(

Be sure to adjust the spring pre-load on the both suspensions equally.

STEERING

CONSTRUCTION

1

Steering head cover

2

Handlebars

3

Handlebar upper clamp

4

Handlebar lower clamp

5

Brake cable guide

6

Steering shaft holder

7

Steering shaft

8

Dust seal

9

Bushing

0

Dust seal

A

O-ring

B

Dust seal

C

Tie rod

D

Tie rod end

A

Handlebar clamp bolt

B

Steering shaft holder bolt

C

Steering shaft nut

D

Tie rod end nut

E

Tie rod locknut

CHASSIS 7-35

@

ITEM

A

B

C

D

E

N•m kgf-m lb-ft

23 2.3

16.5

23

49

2.3

4.9

16.5

35.5

29

29

2.9

2.9

21.0

21.0

7-36 CHASSIS

REMOVAL

Remove the front fender. (

!

7-6)

Remove the master cylinder assembly

1

from the handlebars. (

!

7-26)

Remove the throttle lever case

2

.

Disconnect the rear brake cable

3

and remove the handlebar switch

4

.

Disconnect the fuel vent hose and remove the steering head cover

5

.

Disconnect the indicator lights

6

from the steering head cover.

Remove the clamps

7

PartShark.com

Remove the cotter pins, tie rod end nuts and washers.

$

Replace the removed cotter pins with new ones.

Remove the tie rod ends with a commercially available ball bearing joint remover.

Remove the cotter pin and steering shaft nut

9

, washer

0 and dust seal

A

.

$

Replace the removed cotter pins with new ones.

Remove the O-ring

B

.

Remove the steering shaft holder bolts.

877-999-5686

Remove the steering shaft

C

.

Remove the dust seals

D

from the steering shaft.

Remove the steering shaft holder half

E

.

CHASSIS 7-37

7-38 CHASSIS

Remove the steering shaft.

Remove the dust seal

F

from the steering shaft.

INSPECTION AND DISASSEMBLY

Inspect the removed parts for the following abnormalities.

* Handlebar distortion

* Handlebar clamp wear

DUST SEALS AND O-RING

Inspect the dust seals and O-ring for wear or damage. If any damages are found, replace the dust seals with new ones.

TIE ROD

Inspect the tie rod for distortion or damage. If any damages are found, replace the tie rod with a new one.

1

Tie rod end

2

Locknut

3

Locknut

4

Tie rod

$

877-999-5686

The locknuts

2

with a yellow finished surface have left-hand threads.

TIE ROD END

Inspect the tie rod ends for smooth movement. If there are any abnormalities, replace the tie rod end with a new one.

Inspect the tie rod end boot for wear or damage.

If any damages are found, replace the tie rod end with a new one.

STEERING SHAFT

Inspect the steering shaft for distortion or bends. If any damages are found, replace the steering shaft with a new one.

STEERING SHAFT HOLDER

Inspect the two steering shaft holders for wear or damage. If any damages are found, replace the steering shaft holders with new ones.

STEERING SHAFT BUSHING

Inspect the steering shaft bushing

1

for wear and damage. If any damages are found, replace it with a new one.

Remove the steering shaft bushing with the special tools.

%

PartShark.com

Install the steering shaft bushing with the special tool.

%

09924-84510: Bearing installer set

CHASSIS 7-39

7-40 CHASSIS

REASSEMBLY AND REMOUNTING

Reassemble and remount the steering stem in the reverse order of removal and disassembly. Pay attention to the following points:

STEERING SHAFT

Apply SUZUKI SUPER GREASE to the O-ring, dust seals and steering shaft before remounting the steering shaft.

&

99000-25030: SUZUKI SUPER GREASE A (USA)

99000-25010: SUZUKI SUPER GREASE A (Others)

Install the dust seal

1

to the steering shaft.

Install the new O-ring

2

and dust seal to the steering shaft.

Tighten the steering shaft nut to the specified torque.

"

Steering shaft nut: 49 N•m (4.9 kgf-m, 35.5 lb-ft)

Install new cotter pin.

$ and dust seals before remounting the steering shaft holders.

&

99000-25030: SUZUKI SUPER GREASE A (USA)

99000-25010: SUZUKI SUPER GREASE A (Others)

$

To prevent the entry of dirt, the dust seal end

A

must face forward when installed to the steering shaft.

Tighten the steering shaft holder bolts to the specified torque.

"

Steering shaft holder bolt: 23 N•m (2.3 kgf-m, 16.5 lb-ft)

NOTE:

Make sure that the wiring harness, cables and brake hose routing are properly. (

!

9-12 to -14)

Degrease the tapered portions of the tie rod ends with nonflammable cleaning solvent.

TIE ROD

Install the washers and tighten the tie rod end nuts to the specified torque.

"

Tie rod end nut: 29 N•m (2.9 kgf-m, 21.0 lb-ft)

Install new cotter pins.

$

Replace the removed cotter pins with new ones.

NOTE:

When installing the tie rod, make sure the narrow end

1

of the tie rod comes out.

$

PartShark.com

The locknuts

2

left-hand threads.

877-999-5686

HANDLEBARS

When installing the lower handlebar holder

1

to the steering shaft, the higher mating portion must face to forward.

Set the handlebars to match its punched mark

2

to the mating face of the handlebar clamps.

First tighten the bolts

3

to the specified torque and then tighten the bolts

4

to the specified torque.

"

Handlebar clamp bolt: 23 N•m (2.3 kgf-m, 16.5 lb-ft)

Forward

CHASSIS 7-41

7-42 CHASSIS

Install the steering head cover with the projection

A

inserting into the cushion

B

on the steering head cover bracket.

NOTE:

The indicator light position on the steering head cover is shown on page 8-24.

Install the handle switch with the lug

5

on the switch half inserted into the hole

6

on the handlebars.

NOTE:

After installing the handlebars, make sure that the cable, wiring harness and brake hose routing are properly. (

!

9-12 to -14)

Install the steering head cover.

CHASSIS 7-43

TOE-IN ADJUSTMENT

Adjust the toe-in as follows:

Place the vehicle on level ground and set the handlebars straight.

Make sure all the tires are inflated to the standard pressure.

(

!

2-18)

Place 75 kg (165 lbs) of weight on the seat.

Loosen the locknuts (

1

,

2

) on each tie rod.

$

The locknuts

2

have left-hand threads.

Measure the distances (

A

and

B

) between the front wheels.

Subtract the measurements of

A

from the measurements of

B

to find the toe-in. If the toe-in is not within specification, adjust the tie rod to the right or left until the toe-in is within the specified range.

A B

= Toe-in

'

Toe-in

Standard: 5 – 4 mm (0.20 – 0.16 in)

Forward

Temporarily tighten the four locknuts.

Check that the distances (

C

and

D

) are equal, as shown. If the distances are not equal, adjust the tie rod to the right or left until the toe-in is within specification. Check the toe-in again by measuring distances

A

and

B

.

If the toe-in is not within specification, repeat the adjustment as above until the proper toe-in is obtained and distances

C and

D

become equal.

After adjustment has been made, tighten the four locknuts

1

Right angle

(90 deg.)

"

Tie rod locknut: 29 N•m (2.9 kgf-m, 21.0 lb-ft)

877-999-5686

Forward

7-44 CHASSIS

FRONT WHEEL, FRONT BRAKE, FRONT SUSPENSION AND

STEERING REASSEMBLING INFORMATION

REAR BRAKE

CONSTRUCTION

1

Dust seal

2

Drum cover

3

Brake drum

4

Brake shoe

5

O-ring

6

Snap ring

7

Bearing

8

Brake camshaft

9

O-ring

0

Brake lining indicator plate

A

O-ring

B

Brake panel

C

Brake cam lever

A

Brake panel nut

B

Brake cam lever nut

CHASSIS 7-45

@

ITEM

A

B

C

N•m

60

11

11

kgf-m

6.0

1.1

1.1

lb-ft

43.5

8.0

8.0

7-46 CHASSIS

REMOVAL AND DISASSEMBLY

Raise the rear wheel off the ground and support the vehicle with a jack or wooden block.

Remove the right rear wheel hub. (

!

7-11)

Disconnect the brake cables.

Remove the drum cover bolts.

Remove the drum cover

1

with a flat head screwdriver.

$

* Be careful not to distort the drum cover.

* Distortion of drum cover would cause a malfunction of sealing.

Remove the brake drum

2

.

PartShark.com

Remove the brake shoes

3

and springs

4

.

Remove the O-ring

5

.

NOTE:

If reinstalling the removed brake shoes, mark the brake shoes with direction (leading and trailing) of installation before removing the brake shoes.

Disconnect the brake breather hose.

Remove the brake panel and panel cover

6

.

Remove the O-ring

7

.

Remove the brake cam lever

8

.

Remove the brake lining indicator prate

9

, washer

0

and spring

A

.

Remove the brake camshaft

B

and O-rings panel.

C

from the brake

877-999-5686

CHASSIS 7-47

7-48 CHASSIS

INSPECTION

BRAKE DRUM

Measure the brake drum s I.D. to determine the extent of wear. If the measurement value exceeds the service limit, replace the brake drum with a new one.

'

Brake drum I.D.

Service Limit: 140.7 mm (5.54 in)

BRAKE SHOE

Inspect the brake shoes for wear or damage. If any wear or damages are found, replace the brake shoes with new ones.

$

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

DUST SEAL

Inspect the dust seal on the drum cover for wear or damage.

If any damages are found, replace the dust seal with a new one.

$

Replace the removed dust seal with a new one.

BRAKE PANEL BEARING

the brake panel. Rotate the inner race by hand to inspect for there is anything unusual.

877-999-5686

Remove the snap ring.

Remove the bearing with the special tool.

%

09921-20240: Bearing remover set

$

The removed bearing must be replaced with a new one.

REASSEMBLY AND REMOUNTING

Install new bearing with the special tool.

%

09913-70210: Bearing installer set

Install the snap ring.

removed dust seal

1

.

2

to the drum cover

3

by using the Install new dust seal

877-999-5686

Apply SUZUKI SILICONE GREASE to the dust seal lips.

*

99000-25100: SUZUKI SILICONE GREASE

Drum cover

Dust seal

CHASSIS 7-49

7-50 CHASSIS

Apply SUZUKI SUPER GREASE to new O-rings and brake camshaft.

Install the O-rings and brake camshaft to the anchor panel.

&

99000-25030: SUZUKI SUPER GREASE A (USA)

99000-25010: SUZUKI SUPER GREASE A (Others)

$

O-rings should be replaced with new ones.

Install the washer

4

.

Install the spring

5

with the spring end hocked to the hole on the brake panel.

Align the protrusion

A

of the brake lining indicator prate

6 with the groove

B

of the brake camshaft.

Install the brake lining indicator prate

6

.

"

Install the brake cam lever

7

as its punched mark with the slit

D

on the brake camshaft.

Tighten the cam lever nut to the specified torque.

Cam lever nut: 11 N•m (1.1 kgf-m, 8.0 lb-ft)

C

aligns

877-999-5686

Install new O-ring

8

onto the rear brake panel.

$

O-ring must be replaced with a new one.

Install the brake panel to the rear axle housing.

Install the panel cover

9

.

Tighten the brake panel mounting nuts to the specified torque.

"

Brake panel mounting nut: 60 N•m (6.0 kgf-m, 43.5 lb-ft)

Connect the brake breather hose.

NOTE:

Make sure that the O-ring

8

must be fitted into the groove on the brake panel securely.

Install new O-ring to the brake panel.

$

Replace the removed O-ring with a new one.

Apply SUZUKI SUPER GREASE to the anchor pin and brake camshaft sliding surface lightly.

&

99000-25030: SUZUKI SUPER GREASE A (USA)

99000-25010: SUZUKI SUPER GREASE A (Others)

(

Be careful not to apply too much grease to the brake camshaft and pin. If grease gets on the lining, brake slippage will result.

Install the brake shoes and springs to the brake panel.

$

PartShark.com

NOTE:

* When reinstalling the removed brake shoes, install them in their original position, leading and trailing.

* Make sure that the brake shoe spring s end faces the brake panel as shown.

CHASSIS 7-51

7-52 CHASSIS

Install the brake drum.

$

Do not apply grease to the spline portion of brake drum.

NOTE:

Before installing the brake drum, make sure that the brake drum is clean and free of any greasey matter.

Install the drum cover and tighten the bolts.

NOTE:

When installing the drum cover, make sure that the O-ring must be fitted into the groove on the brake panel securely.

NOTE:

Before connecting the brake cables, make sure that the small-pitch portion of the cable spring faces to the cable adjuster nut.

Connect the brake cables

0

.

PartShark.com

Install the right rear wheel hub. (

!

7-14)

Install the right rear wheel. (

!

7-15)

After installing the rear brake, adjust the following items.

* Brake pedal play .....

!

2-14

* Brake lever play ......

!

2-15

REAR SHOCK ABSORBER

CONSTRUCTION

78 N•m (7.8 kgf-m, 55 lb-ft)

60 N•m (6.0 kgf-m, 43.0 lb-ft)

REMOVAL

Raise the rear wheel off the ground and support the vehicle with a jack or wooden block.

PartShark.com

INSPECTION

REAR SHOCK ABSORBER

Inspect the rear shock absorber body and rubber bushing for damage and leakage of oil.

If any defects are found, replace the rear shock absorber with a new one.

$

Do not attempt to disassemble the rear shock absorber and to bleed out the nitorogen gas. It is unserviceble.

CHASSIS 7-53

7-54 CHASSIS

REAR SHOCK ABSORBER SPACER AND BEARING

Remove the spacers and dust seals.

$

The removed dust seals must be replaced with new ones.

Inspect the spacers for any flaws or other damage. If any damages are found, replace the spacers with new ones.

Insert the spacer into the rear shock absorber bearing and then check the play by moving the spacer up and down.

If excessive play is noted, replace the bearing with a new one.

Remove the rear shock absorber bearing with the special tools.

%

09923-73210: Bearing remover

09930-30104: Sliding shaft

$

The removed bearing must be replaced with a new one.

REASSEMBLY

NOTE:

Press the bearing into the rear shock absorber to the depth of wrench.

877-999-5686

When installing the rear shock absorber bearing, make sure that the stamped mark faces right side.

%

09924-84521: Bearing installer set

REMOUNTING

Tighten the upper and lower shock absorber mounting nuts to the specified torque of each.

"

Rear shock absorber mounting nut (Upper):

78 N•m (7.8 kgf-m, 55 lb-ft)

Rear shock absorber mounting nut (Lower):

60 N•m (6.0 kgf-m, 43.0 lb-ft)

SUSPENSION SETTING

SPRING PRE-LOAD ADJUSTMENT

The rear suspension spring pre-load is adjustable. This adjustment is performed by changing spring set length.

Loosen the locknut

1

.

Adjust the spring set length by turning the adjuster

2

.

SPRING SET LENGTH

A

STANDARD

MAXIMUM

(SOFTEST)

232.5 mm

(9.15 in)

235 mm

(9.25 in)

$

MINIMUM

(STIFFEST)

227 mm

(8.94 in)

Do not set the spring length out of the specified range.

Tighten the locknut

1

.

REAR SHOCK ABSORBER DISPOSAL

(

* The rear shock absorber unit contains high-pressure nitrogen gas.

* Mishandling can cause explosion.

* Keep away from fire and heat. High gas pressure caused by heat can cause an explosion.

* Release gas pressure before disposing.

GAS PRESSURE RELEASE

Press the valve with a screwdriver to bleed out the nitrogen gas.

(

PartShark.com

* Releasing high pressure gas from the rear shock absorber unit can be hazardous. Never perform any servicing until the nitrogen gas pressure has been released from the rear shock absorber unit.

* When releasing the gas pressure, place a reg over the gas valve and use the tip of a screwdriver to press the valve. Do not use your finger to depress the gas valve, and be sure to direct the valve away from your face and body.

* Be sure to always wear eye protection when performing this procedure.

CHASSIS 7-55

7-56 CHASSIS

REAR SUSPENSION

CONSTRUCTION

1

Rear shock absorber

2

Swingarm

3

Bearing

A

Rear shock absorber mounting nut (Upper)

B

Rear shock absorber mounting nut (Lower)

C

Swingarm pivot nut

D

Axle housing mounting nut (RH)

E

Axle housing bolt

F

Axle housing mounting nut (LH)

@

ITEM

A

B

C

D

EF

N•m kgf-m

78 7.8

60

85

60

65

6.0

8.5

6.0

6.5

lb-ft

55.0

43.5

61.5

43.5

47.0

REMOVAL

Remove the footrest mud guards. (

!

7-7)

Remove the rear drive gear case assembly. (

!

4-3)

Remove the rear shock absorber. (

!

7-53)

Disconnect the brake breather hose

2

from the swingarm.

Loosen the swingarm pivot bolts/nuts

3

.

Remove the swingarm.

INSPECTION AND DISASSEMBLY

REAR SHOCK ABSORBER

Inspect the rear shock absorber. (

!

7-53)

SPACER

Remove the dust covers

1

and spacers

2

from the swingarm.

Inspect the spacers

2

for any flaws or other damage. If any defects are found, replace the spacer with a new one.

SWINGARM

PartShark.com

Inspect the swingarm for distortion or damage. If any damage are found, replace the swingarm with a new one.

CHASSIS 7-57

7-58 CHASSIS

SWINGARM PIVOT BEARING

Insert the spacer into the swingarm pivot bearings and then check the play by moving the spacer up and down.

If excessive play is noted, replace the bearing with a new one.

Remove the swingarm pivot bearing with the special tools.

%

09923-74510: Bearing remover

09930-30104: Sliding shaft

$

The removed bearing must be replaced with a new one.

REASSEMBLY

SWINGARM PIVOT BEARING AND DUST SEAL

Press the bearing into the swingarm pivot to the depth of 5.0

mm (0.197 in) from the outside with the special tool and suitable socket wrench.

NOTE:

When installing the swingarm pivot bearing, make sure that the stamped mark faces outside.

%

09924-84510: Bearing installer set

and ips of the dust covers.

&

877-999-5686

REMOUNTING

Remount the rear swingarm and suspension in the reverse order of removal. Pay attention to the following points:

Apply THREAD LOCK SUPER to the swingarm pivot bolts.

Install the swingarm pivot bolts and upper and lower shock absorber mounting bolts temporarily.

Tighten the swingarm pivot nut to the specified torque.

,

99000-32030: THREAD LOCK SUPER 1303 (USA)

-

99000-32110: THREAD LOCK SUPER 1322 (Others)

"

Swingarm pivot nut: 85 N•m (8.5 kgf-m, 61.5 lb-ft)

Tighten the upper and lower shock absorber mounting nuts to the specified torque of each.

"

Rear shock absorber mounting nut (Upper):

78 N•m (7.8 kgf-m, 55 lb-ft)

Rear shock absorber mounting nut (Lower):

60 N•m (6.0 kgf-m, 43.0 lb-ft)

CHASSIS 7-59

7-60 CHASSIS

REAR AXLE

CONSTRUCTION

Do not apply grease to the spline portion of the brake drum.

1

Rear axle

2

Rear axle housing

65 N•m (6.5 kgf-m, 47 lb-ft)

REMOVAL

Remove the rear wheels. (

!

7-11)

Remove the rear wheel hubs. (

!

7-11)

Remove the rear brake. (

!

7-46)

Remove the rear axle housing/final gear case bolts

1

and rear axle housing set bolts/nuts

2

.

Remove the rear axle housing

3

and rear axle

4

.

Remove the O-ring

5

.

INSPECTION

REAR AXLE SHAFT

Inspect the rear axle shaft visually for distortion or damages. If one.

any damages are found, replace the rear axle shaft with a new

PartShark.com

Using a dial gauge, check the axle shaft for runout and replace it if the runout exceeds the limit.

877-999-5686

"

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

09900-20701: Magnetic stand

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

#

Axle shaft runout

Service Limit: 3.0 mm (0.12 in)

CHASSIS 7-61

7-62 CHASSIS

REAR AXLE HOUSING

Inspect the rear axle housing for distortion or damages. If any damages are found, replace the rear axle housing with a new one.

REASSEMBLY AND REMOUNTING

Reassemble and remount the rear axle in reverse order of removal and disassembly. Pay attention to the following points:

Apply SUZUKI SUPER GREASE to the rear drive case spline.

&

99000-25030: SUZUKI SUPER GREASE A (USA)

99000-25010: SUZUKI SUPER GREASE A (Others)

Install new O-ring to the rear drive gear case.

NOTE:

Before installing the O-ring, apply grease to it.

Install the rear axle shaft and rear axle housing to the rear drive gear case.

Apply THREAD LOCK SUPER to the rear axle housing/final gear case bolts

1

and rear axle housing set bolts

2

.

Tighten the rear axle housing/final gear case bolts

1

and rear

" axle housing set nuts

2

to the specified torque of each.

,

99000-32030: THREAD LOCK SUPER 1303 (USA)

-

PartShark.com

Rear axle housing set nut:

65 N•m (6.5 kgf-m, 47.0 lb-ft)

60 N•m (6.0 kgf-m, 43.5 lb-ft)

CHASSIS 7-63

REAR WHEEL, REAR BRAKE, REAR SUSPENSION, REAR SWIN-

GARM AND REAR AXLE SHAFT REASSEMBLING INFORMATION

7-64 CHASSIS

REVERSE LOCK RELEASE CABLE

REMOVAL

Remove the reverse lock release knob

1

from the front fender.

Open the fixed clamp.

Remove the clip

2

and pin

3

.

Loosen the locknuts

4

and remove the reverse lock release cable.

Remove the bracket

5

.

Remove the cap

6

.

PartShark.com

Remove the screw

7

and washers

8

.

Remove the knob

9

.

Disconnect the cable by removing the rotor

0

.

REMOUNTING

Remount the reverse lock release cable in the reverse order of removal. Pay attention to the following points:

Install the spring so that the spring end

A

matches the groove

B

on the housing.

Apply SUZUKI SUPER GREASE to the O-ring

&

1

.

PartShark.com

Install the O-ring

1 to the reverse lock release cable

2

.

Connect the cable to the rotor

3

through the hole of the housing.

99000-25010: SUZUKI SUPER GREASE A (Others)

877-999-5686

NOTE:

* When installing the rotor, hook the spring end

C

on the concave portion

D

of the rotor.

* Make sure that the reverse lock release cable is routed correctly.

CHASSIS 7-65

7-66 CHASSIS

CABLE PLAY ADJUSTMENT

After installing the reverse lock release cable, adjust the cable play.

Loosen the locknuts

1

.

Slide the adjuster

2

until the cable play at the reverse lock release knob

A

reaches 1 2 mm (0.04 0.08 in).

Tighten the locknuts

1

securely.

After adjustment, be sure to check for reverse lock function.

ELECTRICAL SYSTEM

ELECTRICAL SYSTEM 8-1

CONTENTS

CAUTIONS IN SERVICING ..........................................................................8- 2

CONNECTORS .......................................................................................8- 2

COUPLERS .............................................................................................8- 2

CLAMPS ..................................................................................................8- 2

FUSES .....................................................................................................8- 2

SEMI-CONDUCTOR EQUIPPED PARTS ...............................................8- 2

BATTERY ................................................................................................8- 3

CONNECTING THE BATTERY...............................................................8- 3

WIRING PROCEDURE............................................................................8- 3

USING THE MULTI CIRCUIT TESTER...................................................8- 3

LOCATION OF ELECTRICAL COMPONENTS ...........................................8- 4

CHARGING SYSTEM ...................................................................................8- 6

TROUBLE SHOOTING ...........................................................................8- 6

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

STARTER SYSTEM ......................................................................................8-11

TROUBLE SHOOTING ...........................................................................8-11

STARTER MOTOR REMOVAL AND DISASSEMBLY ...........................8-13

STARTER MOTOR INSPECTION...........................................................8-13

STARTER MOTOR REASSEMBLY AND REMOUNTING .....................8-14

STARTER RELAY INSPECTION ............................................................8-15

NEUTRAL RELAY INSPECTION............................................................8-16

PARKING BRAKE SWITCH ...................................................................8-16

IGNITION SYSTEM .......................................................................................8-17

TROUBLESHOOTING ............................................................................8-17

PartShark.com

BRAKE LIGHT/TAILLIGHT.....................................................................8-23

INSPECTION ...........................................................................................8-24

INDICATOR LIGHT POSITION ...............................................................8-24

DIODE ...........................................................................................................8-25

SWITCHES ...................................................................................................8-26

BATTERY .....................................................................................................8-27

SPECIFICATIONS...................................................................................8-27

INITIAL CHARGING ................................................................................8-27

SERVICING .............................................................................................8-29

RECHARGING OPERATION ..................................................................8-29

8

8-2 ELECTRICAL SYSTEM

CAUTIONS IN SERVICING

CONNECTORS

When disconnecting a connector, be sure to hold the terminals; do not pull the lead wires.

When connecting a connector, push it in so it is firmly attached.

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

COUPLERS

With a lock-type coupler, be sure to release the lock before disconnecting it. When connecting a coupler, push it in until the lock clicks shut.

When disconnecting a coupler, be sure to hold the coupler; do not pull the lead wires.

Inspect each terminal on the coupler for looseness or bends.

Inspect each terminal for corrosion and contamination.

CLAMPS

Refer to the WIRING HARNESS ROUTING section for proper clamping procedures. (

!

9-11 to -14)

Bend the clamp properly, as shown in the illustration.

When clamping the wire harness, do not allow it to hang down.

Do not use wire or any substitutes for the band-type clamp.

FUSES

When a fuse blows, always investigate the cause, correct the problem, and then replace the fuse.

877-999-5686

SEMI-CONDUCTOR EQUIPPED PARTS

Do not drop any part that contains a semi-conductor (e.g.,

CDI unit, regulator/rectifier).

When inspecting the part, follow the inspection instructions carefully. Neglecting proper procedures may cause this part to be damaged.

INCORRECT

ELECTRICAL SYSTEM 8-3

BATTERY

The MF battery used in this vehicle does not require maintenance (e.g., electrolyte level inspection, distilled water replenishment).

During normal charging, no hydrogen gas is produced. However, if the battery is overcharged, hydrogen gas may be produced. Therefore, be sure there are no fire or spark sources

(e.g., short circuit) nearby when charging the battery.

Be sure to recharge the battery in a well-ventilated and open area.

Note that the charging system for the MF battery is different from that of a conventional battery. Do not replace the MF battery with a conventional battery.

CONNECTING THE BATTERY

When disconnecting terminals from the battery for disassembly or servicing, be sure to disconnect the

-

battery lead wire, first.

When connecting the battery lead wires, be sure to connect the

+

battery lead wire, first.

If the terminal is corroded, remove the battery, pour warm water over it and clean it with a wire brush.

After connecting the battery, apply a light coat of grease to the battery terminals.

Install the cover over the

+

battery terminal.

WIRING PROCEDURE

Properly route the wire harness according to the WIRING

HARNESS ROUTING section. (

!

9-11 to -14)

PartShark.com

USING THE MULTI CIRCUIT TESTER

Properly use the multi circuit tester

+

and

-

probes.

Improper use can cause damage to the vehicle and tester.

If the voltage and current values are not known, begin measuring in the highest range.

When measuring the resistance, make sure no voltage is applied. If voltage is applied, the tester will be damaged.

After using the tester, be sure to turn the switch to the OFF position.

"

Before using the multi circuit tester, read its instruction manual.

8-4 ELECTRICAL SYSTEM

LOCATION OF ELECTRICAL COMPONENTS

1

CDI unit

2

Battery

3

Fuse

4

Ignition switch

5

Front brake light switch

6

Rear brake light pedal switch

7

Starter motor

1

Handlebar switch (L)

2

Rear brake light switch

3

Parking brake switch

4

Neutral switch diode

5

Fuse

6

Starter relay

7

Ignition coil

8

Generator

9

Neutral switch

0

Regulator/rectifier

A

Neutral relay

ELECTRICAL SYSTEM 8-5

8-6 ELECTRICAL SYSTEM

CHARGING SYSTEM

Ignition switch

Fuse

Battery

Generator

Regulator/rectifier

TROUBLE SHOOTING

Battery runs down quickly.

Step 1

1) Check accessories which use excessive amounts of electricity.

Are accessories being installed ?

YES Remove accessories

NO

Step 2

1) Check the battery for current leaks. (

!

8-8)

YES

NO

Go to Step 2.

PartShark.com

Go to Step 3.

877-999-5686

Short circuit of wire harness

Faulty electrical equipment

Step 3

1) Measure the regulated voltage between the battery terminals. (

!

8-8)

Is the battery charging of voltage OK ?

YES

NO

Faulty battery

Abnormal driving condition

Go to Step 4.

<Continued on next page>

ELECTRICAL SYSTEM 8-7

Step 4

1) Measure the resistance of the generator coil. (

!

8-9)

Is the resistance of generator coil OK ?

YES

NO

Go to Step 5.

Faulty generator coil or disconnected lead wires

Step 5

1) Measure the generator no-load voltage. (

!

8-9)

Is the generator no-load voltage OK ?

YES

NO

Go to Step 6.

Faulty generator

Step 6

1) Inspect the regulator/rectifier. (

!

8-10)

Is the regulator/rectifier OK ?

YES

NO

Go to Step 7.

Faulty regulator/rectifier

Step 7

1) Inspect the wirings.

Are the wirings OK ?

YES

NO

Faulty battery

Short circuit of wire harness

Poor contact of couplers

Battery overcharge

Faulty regulator/rectifier

Faulty battery

Poor contact of generator lead wire coupler

877-999-5686

8-8 ELECTRICAL SYSTEM

INSPECTION

BATTERY CURRENT LEAKAGE

Remove the seat. (

!

7-5)

Turn the ignition switch to the OFF position.

Disconnect the

-

battery lead wire

1

.

Measure the current between the

-

battery terminal and the

battery lead wire using the multi circuit tester. If the reading exceeds the specified value, leakage is evident.

#

Battery current (leak): Under 1.0 mA

$

09900-25008: Multi circuit tester set

%

Tester knob indication: Current (

&

, 20 mA)

"

* Because the current leak might be large, turn the tester to the high range first to avoid tester damage.

* Do not turn the ignition switch to the ON position when measuring current.

When checking to find the excessive current leakage, remove the couplers and connectors, one by one, checking each part.

REGULATED VOLTAGE

Remove the seat. (

!

7-5)

Remove the battery holder

1

.

Shift the transmission to the neutral position.

Start the engine, turn the ignition switch to LIGHT(

'

) and the dimmer switch to HI and run the engine at 5 000 r/min.

Battery

DC mA

Measure the DC voltage between the

+

and

-

battery terminals using the multi circuit tester. If the voltage is not within the

(

!

8-9 to -10)

877-999-5686

NOTE:

When making this test, be sure that the battery is in fully-

DC V

charged condition.

#

Regulated voltage: 14.0 15.5 V at 5 000 r/min

$

09900-25008: Multi circuit tester set

(

Tester knob indication: Voltage (

&

)

ELECTRICAL SYSTEM 8-9

GENERATOR COIL RESISTANCE

Remove the left fuel tank side cover. (

!

7-5)

Disconnect the generator lead wire coupler.

Measure the resistance among the three lead wires.

If the resistance is not specified value, replace the stator coil with a new one.

Also, check that the generator core is insulated.

#

Generator coil resistance: 0.5 1.2

Ω

(Yellow Yellow)

∞ Ω

(Yellow Ground)

$

09900-25008: Multi circuit tester set

)

Tester knob indication: Resistance (

Ω

)

GENERATOR NO-LOAD PERFORMANCE

Remove the left fuel tank side cover. (

!

7-5)

Disconnect the generator lead wire coupler.

Shift the transmission to the neutral position.

Start the engine and run it at 5 000 r/min.

Measure the AC voltage among the lead wires using the multi circuit tester.

If the voltage is under the specified value, replace the AC generator with a new one.

#

$

(

Generator no-load performance (when engine is cold):

65 V and more (AC) at 5 000 r/min

09900-25008: Multi circuit tester set

877-999-5686

8-10 ELECTRICAL SYSTEM

REGULATOR/RECTIFIER

Remove the regulator/rectifier.

Measure the voltage between the terminals using the multi circuit tester, as indicated in the table below.

If the voltage is not within the specified value, replace the regulator/rectifier with a new one.

$

09900-25008: Multi circuit tester set

*

Tester knob indication: Diode test (

+

)

Unit: V

A B

+

Tester probe

C D E F

A

B

C

D

E

F

✽

✽

✽

✽

✽

✽

0.5 1.2 0.4 0.7 0.4 0.7 0.4 0.7

✽

✽

✽

✽

0.4 0.7

0.4 0.7

✽

✽

✽

✽

0.4 0.7

✽

✽

More than 1.4 V (tester s battery voltage)

✽

✽

✽

✽

✽

✽

✽

✽

NOTE:

If the tester reads under 1.4 V when the tester probes are not

877-999-5686

ELECTRICAL SYSTEM 8-11

STARTER SYSTEM

Starter motor

Starter relay

B/W

Fuse

R/W

Starter button

Engine stop switch

Y/B

Neutral relay

O

B/G

B/Bl

Neutral indicator light

Bl

Bl/R

Reverse indicator light

Parking brake switch

R

Neutral switch

Ignition switch

CDI

W

TROUBLE SHOOTING

Starter motor will not run.

Step 1

1) The transmission is in neutral. Turn on the ignition switch with the engine stop switch in the RUN position.

2) Listen for a click from the starter relay when the starter button is pushed.

Is a click sound heard ?

NO

YES Go to Step 2.

NO

Step 2

Go to Step 3.

wire because a large amount of current flows.)

Does the starter motor run ?

877-999-5686

Faulty starter relay

+

battery terminal. (Do not use thin

YES

Loose or disconnected starter motor lead wire

Faulty starter motor

<Continued on next page>

8-12 ELECTRICAL SYSTEM

Step 3

1) Measure the starter relay voltage at the starter relay connectors (between Y/B

+

and B/W

-

) when the starter button is pushed.

Is the voltage OK ?

YES

NO

Go to Step 4.

Faulty ignition switch

Faulty engine stop switch

Faulty neutral relay

Faulty neutral switch

Faulty starter button

Poor contact of connector

Open circuit in wire harness

Step 4

1) Check the starter relay. (

!

8-15)

Is the starter relay OK ?

YES

NO

NOTE:

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 parking lever grasp firmly.

2) Check the parking brake switch. (

!

8-26)

Is the parking brake switch OK ?

YES

NO

Poor contact of the starter relay

Faulty starter relay

Open circuit in wire harness

Poor contact of connector

Faulty parking brake switch

Engine does not turn though the starter motor runs.

Faulty starter clutch. (

!

3-40)

877-999-5686

STARTER MOTOR REMOVAL AND DISAS-

SEMBLY

Remove the starter motor

1

.

Disassembly the starter motor, as shown.

ELECTRICAL SYSTEM 8-13

Housing end (outside)

Brush holder

Brush spring

O-ring

Brush terminal set

Starter motor case

Washer set

Armature

Housing end (inside)

O-ring

CARBON BRUSHES

Inspect the carbon brushes for abnormal wear, cracks, or smoothness in the brush holder.

new one.

877-999-5686

COMMUTATOR

Inspect the commutator for discoloration, abnormal wear or undercut

A

.

If abnormal wear is found, replace the armature with a new one.

If the commutator surface is discolored, polish it with #400 sandpaper and wipe it using a clean, dry cloth.

If there is no undercut, scrape out the insulator

1

with a saw blade.

8-14 ELECTRICAL SYSTEM

ARMATURE COIL INSPECTION

Check for continuity between each segment, and between each segment and the armature shaft using the multi circuit tester.

If there is no continuity between the segments or there is continuity between the segments and shaft, replace the armature with a new one.

$

09900-25008: Multi circuit tester set

,

Tester knob indication: Continuity test (

-

)

OIL SEAL

Check the seal lip for damage or leakage. If any damages are found, replace the starter motor with a new one.

STARTER MOTOR REASSEMBLY AND

REMOUNTING

Reassemble and remount the starter motor in the reverse order of removal and disassembly. Pay attention to the following points:

"

Replace the removed O-rings with new ones to prevent oil leakage and moisture.

Apply SUZUKI SUPER GREASE to the lip of the oil seal.

.

PartShark.com

Apply a small quantity of SUZUKI MOLY PASTE to the armature shaft.

/

99000-25140: SUZUKI MOLY PASTE

Align the match marks on the starter motor case with the match mark on the housing end.

Apply a small quantity of THREAD LOCK to the starter motor housing bolts and tighten it securely.

0

99000-32050: THREAD LOCK 1342

Apply SUZUKI SUPER GREASE to the O-ring.

.

99000-25030: SUZUKI SUPER GREASE A (USA)

99000-25010: SUZUKI SUPER GREASE A (Others)

STARTER RELAY INSPECTION

Remove the left fuel tank side cover. (

!

7-5)

Disconnect the

-

battery lead wire from the battery terminal.

(

!

8-8)

Open the starter relay cover

1

.

Disconnect the starter motor lead wire

1

and battery lead wire

2

PartShark.com

ELECTRICAL SYSTEM 8-15

8-16 ELECTRICAL SYSTEM

Apply 12 V to the terminals and check for continuity between the positive and negative terminals using the multi circuit tester. If the starter relay clicks and continuity is found, the relay is OK.

$

09900-25008: Multi circuit tester set

,

Tester knob indication: Continuity test (

-

)

"

Do not apply a battery voltage to the starter relay for more than five seconds.

This may overheat and damage the relay coil.

Measure the relay coil resistance between the terminals using the multi circuit tester. If the resistance is not within the specified value, replace the starter relay with a new one.

#

Starter relay resistance

Standard: 3 6

Ω

$

09900-25008: Multi circuit tester set

)

Tester knob indication: Resistance (

Ω

)

NEUTRAL RELAY INSPECTION

Remove the neutral relay.

PartShark.com

continuity between

A

and

B

. If there is no continuity, replace the neutral relay with a new one.

$

09900-25008: Multi circuit tester set

,

Tester knob indication: Continuity set (

-

)

PARKING BRAKE SWITCH

(

!

8-26)

ELECTRICAL SYSTEM 8-17

IGNITION SYSTEM

Fuse

Ignition switch

Engine stop switch

CDI unit

Ignition coil

Battery

Generator

Spark plug

Parking brake switch

Neutral relay

Neutral switch

NO

TROUBLESHOOTING

NOTE:

* Check that the transmission is in neutral and the engine stop switch is in the RUN position. Check that the fuse is not blown and the battery is fully-charged before diagnosing.

No spark or poor spark

Step 1

1) Check the ignition system couplers for poor connections.

Is there connection in the ignition switch couplers ?

YES

NO

Step 2

PartShark.com

in the ON position.

877-999-5686

1) Measure the battery voltage between input lead wires (O/W and B/W) at the CDI with the ignition switch

Is the voltage OK ?

YES Go to Step 3.

Faulty ignition switch

Faulty engine stop switch

Broken wire harness or poor connection of related circuit couplers

<Continued on next page>

8-18 ELECTRICAL SYSTEM

Step 3

1) Measure the ignition coil primary peak voltage. (

!

8-19)

NOTE:

This inspection method is applicable only with the multi circuit tester and the peak volt adaptor.

Is the peak voltage OK ?

YES

NO

Go to Step 4.

Go to Step 5.

Step 4

1) Inspect the spark plug. (

!

2-7)

Are the spark plug OK ?

YES

NO

Poor connection of the spark plug cap

Go to Step 5.

Faulty spark plug

Step 5

1) Inspect the ignition coil. (

!

8-20)

Are the ignition coil OK ?

YES

NO

Go to Step 6.

Faulty ignition coil

NO

Step 6

1) Measure the pickup coil peak voltage and its resistance. (

!

8-20 to -21)

NOTE:

The pickup coil peak voltage inspection is applicable only with the multi circuit tester and peak volt adaptor.

Are the peak voltage and its resistance OK ?

YES

Faulty CDI

Open circuit in wiring harness.

Poor connection of ignition couplers

877-999-5686

ELECTRICAL SYSTEM 8-19

INSPECTION

IGNITION COIL PRIMARY PEAK VOLTAGE

Disconnect the spark plug cap.

Connect a new spark plug to the spark plug cap and ground it to the cylinder head.

NOTE:

Make sure that the spark plug cap and spark plug are connected properly and the battery is fully-charged.

Measure the ignition coil primary peak volt using the multi circuit tester in the following procedure:

Connect the multi circuit tester with the peak voltage adaptor as follows.

+

Probe: Black/White lead wire

-

Probe: White/Blue lead wire

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, refer to the appropriate instruction manual.

Peak volt adaptor

Ignition coil

Shift the transmission to the neutral position and turn the ignition switch to the ON position.

Press the starter button and allow the engine to crank for a few seconds, and then measure the ignition coil primary peak

CDI unit voltage.

Repeat the above procedure a few times and measure the

#

Ignition coil primary peak voltage: 120 V and more

(

1

PartShark.com

While testing, do not touch the tester probes and spark plug to prevent receiving an electric shock.

Battery

New spark plug

If the voltage is lower than the standard values, inspect the ignition coil. (

!

8-20)

8-20 ELECTRICAL SYSTEM

IGNITION COIL RESISTANCE

Disconnect the ignition coil lead wires and spark plug cap.

Measure the ignition coil resistance in both the primary and secondary windings using the multi circuit tester. If the resistance in both the primary and secondary windings is close to the specified values, the windings are in sound condition.

#

Ignition coil resistance

Primary : 0.05 1.0

Ω

(

+

Secondary : 10.5 19.0 k

Ω

Terminal

-

Terminal)

(Spark plug cap

+

Terminal)

$

09900-25008: Multi circuit tester set

)

Tester knob indication: Resistance (

Ω

)

PICKUP COIL PEAK VOLTAGE

NOTE:

Make sure all of the couplers are connected properly.

Remove the seat. (

!

7-5)

Disconnect the CDI unit coupler

1

.

Measure the pickup coil peak voltage in the following procedure: follows.

Pickup coil:

"

+

-

PartShark.com

$

09900-25008: Multi circuit tester set

Generator

B/Y

G/W

B/Y

G/W

Pickup coil

Wiring harness coupler

Peak volt adaptor

When using the multi circuit tester and peak volt adaptor, refer to the appropriate instruction manual.

ELECTRICAL SYSTEM 8-21

Shift the transmission to the neutral position, turn the ignition switch to the ON position.

Press the starter button and allow the engine to turn for a few seconds, and then measure the pickup coil peak voltage.

Repeat the above procedure a few times and measure the highest pickup coil peak voltage.

#

Pickup coil peak voltage: 4.0 V and more

(

Tester knob indication: Voltage (

&

)

If the peak voltage measured on the CDI unit coupler is lower than the standard value, measure the peak voltage on the generator coupler as follows:

Remove the left fuel tank side cover. (

!

7-5)

Disconnect the generator coupler and connect the multi circuit tester with the peak volt adaptor as follows.

Pickup coil:

+

Probe...Green/White lead wire

-

Probe...Blue/Yellow lead wire

Measure the pickup coil peak voltage in the same manner as on the CDI unit coupler.

#

Pickup coil peak voltage: 4.0 V and more

(

Tester knob indication: Voltage (

&

)

B/Y

G/W

Generator

If the peak voltage on the generator coupler is within the specification, but on the CDI unit coupler is not within specification, replace the wire harness with a new one. If both peak voltages are out of specification, replace the generator with a new one.

PartShark.com

Disconnect the generator coupler.

circuit tester. If the resistance is not within the specified value,

Pickup coil

877-999-5686

stator coil must be replaced.

#

Pickup coil resistance: 80 155

Ω

(B/Y G/W)

$

09900-25008: Multi circuit tester set

(

Tester knob indication: Resistance (

Ω

)

Peak volt adaptor

8-22 ELECTRICAL SYSTEM

LAMPS

HEADLIGHT

Head light: 12 V 40/40 W

7.8 N•m (0.78 kgf-m, 5.6 lb-ft)

E-28 ONLY

1.8 N•m

(0.18 kgf-m, 1.3 lb-ft)

!

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 BULB REPLACEMENT

Remove the bulb.

PartShark.com

HEADLIGHT BEAM ADJUSTMENT

Adjust the headlight vertical beam by loosening the screw

1

.

BRAKE LIGHT/TAILLIGHT

ELECTRICAL SYSTEM 8-23

Brake light/taillight: 12 V 21/5 W

"

E-28 Only

877-999-5686

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.

BULB REPLACEMENT

Disconnect the socket.

Remove the bulb.

Install new bulb in the reverse order of removal.

8-24 ELECTRICAL SYSTEM

INDICATOR LIGHT

INSPECTION

RE NU

Steering stem head cover

ITEM

RE: Reverse indicator light

NU: Neutral indicator light

WIRE COLOR

Bl/B

Bl/R

: Blue with Black tracer

: Blue with Red tracer

O/Bl : Orange with Blue tracer

+

O/Bl

O/Bl

-

Bl/R

Bl/B

Neutral indicator light

(Bl/B & O/Bl)

LB LR

Steering stem head cover

Reverse indicator light

(Bl/R & O/Bl)

WIRE COLOR

Bl/B : Blue with Black tracer

Bl/R : Blue with Red tracer

O/Bl: Orange with Blue tracer

DIODE

Remove the fuel tank left side cover. (

!

7-5)

Remove the neutral switch diode

1

.

Measure the voltage between the terminals using the multi circuit tester as indicated in the table below.

"

09900-25008: Multi circuit tester set

#

Tester knob indication: Diode test (

$

)

Unit: V

A

+

Tester probe

B

✽

A

B

0.4 0.6

C

✽ ✽

✽

More than 1.4 V (tester s battery voltage)

C

✽

0.4 0 .6

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 8-25

8-26 ELECTRICAL SYSTEM

SWITCHES

Measure each switch for continuity using the multi circuit tester. If any abnormality is found, replace the respective switch assemblies with a new one.

"

09900-25008: Multi circuit tester set

IGNITION SWITCH

Position

Color

R O Gr

NEUTRAL SWITCH

Position

Color

Bl

Neutral

Reverse

Others

R

B/W

STARTER BUTTON

Position

Color

O/W Y/G

PARKING BRAKE SWITCH

Position

Color

B/W

ON

OFF

B/Bl

BRAKE LIGHT LEVER SWITCH (R)

Position

Color

Terminal

ON

OFF

Terminal

DIMMER SWITCH

Position

Color

Y W

BRAKE LIGHT LEVER SWITCH (L)

Position

Color

B

ON

OFF

B

ENGINE STOP SWITCH

Position

Color

O

BRAKE LIGHT PEDAL SWITCH

Position

ON

OFF

Color

O W/B

WIRE COLOR

B : Black

PartShark.com

R : Red

Y : Yellow

B/Bl : Black with Blue tracer

B/W : Black with White tracer

O/W : Orange with White tracer

O/G : Orange with Green tracer

W/B : White with Black tracer

Y/G : Yellow with Green tracer

O/W

Gr

ELECTRICAL SYSTEM 8-27

BATTERY

SPECIFICATIONS

Type designation

Capacity a

Anode plates b

Separator (fiberglass plate) c

Cathode plates d

Upper cover breather

YTX9-BS

12 V, 28.8 kC (8 Ah)/10 HR e

Stopper f

Filter g

Terminal h

Safety valve

INITIAL CHARGING

FILLING ELECTROLYTE

Remove the aluminum tape

1

sealing the battery electrolyte filler holes

2

.

Remove the caps

3

.

NOTE:

* After filling the electrolyte completely, use the removed caps

3

as the sealing caps of the battery electrolyte filler holes.

* Do not remove or pierce the sealed portions

4

of the electrolyte container.

Insert the nozzles of the electrolyte container

5

into the battery electrolyte filler holes, holding the container firmly so that to spill.

877-999-5686

8-28 ELECTRICAL SYSTEM

Make sure that air bubbles

6

are coming up into each electrolyte container, and leave it in this position for more than 20 minutes.

NOTE:

If no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times.

Never remove the container from the battery.

After confirming that the electrolyte has entered the battery completely, remove the electrolyte container from the battery.

Wait for more than 20 minutes.

Insert the caps

3

into the filler holes, pressing in firmly so that the caps do not protrude above the upper surface of the battery top cover.

"

* Never use anything except the specified battery.

* Once install the caps to the battery; do not remove the caps.

* Do not tap the caps with a hammer when installing them.

CORRECT

For initial charging, use a charger specially designed for MF batteries.

INCORRECT

ELECTRICAL SYSTEM 8-29

"

* For charging the battery, make sure to use a charger specially designed for MF batteries. Otherwise, the battery may be overcharged resulting in shortned service life.

* Do not remove the caps while charging.

* Position the battery with the cap facing upward while charging.

SERVICING

Visually inspect the surface of the battery. If any signs of cracking or electrolyte leakage 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, clean the battery terminals with sandpaper.

RECHARGING OPERATION

Measure the battery voltage with the multi circuit tester. If the voltage reading is less than 12 V (DC), recharge the battery with a battery charger.

$

09900-25008: Multi circuit tester set

"

* When recharging the battery, remove the battery from the vehicle.

* Do not remove the caps while recharging.

Recharging time: 0.9 A for 5 to 10 hours or 4 A for 1 hour.

"

exceed 4 A at any time.

(V)

14

13

12

11

10

(at 0 40 ßC, 32 — 104 ßF)

100 75 50 25

Battery charged condition

0 (%) the battery voltage with the multi circuit tester. If the battery voltage is less than 12.5 V, recharge the battery again. If the battery voltage is still less than 12.5 V after recharging twice, replace the battery with a new one.

When a battery is left unused for a long time, its voltage needs to be regularly measured. When the vehicle is not used for more than one month (especially during the winter season), measure the battery voltage at least once a month.

15

14

13

12

(V)

18

17

16

Charging period

Stop charging

0 10 20 30 40 50 60

Time

(Minutes)

 

SERVICING INFORMATION

SERVICING INFORMATION 9-1

CONTENTS

TROUBLESHOOTING .................................................................................. 9- 2

ENGINE .................................................................................................. 9- 2

DRIVE TRAIN ........................................................................................ 9- 5

CARBURETOR ...................................................................................... 9- 5

CHASSIS ............................................................................................... 9- 6

BRAKES ................................................................................................ 9- 7

ELECTRICAL ......................................................................................... 9- 8

BATTERY .............................................................................................. 9- 9

WIRING DIAGRAM ....................................................................................... 9-10

WIRING HARNESS, CABLE, AND HOSE ROUTING .................................. 9-11

WIRING HARNESS ROUTING .............................................................. 9-11

CABLE ROUTING ................................................................................. 9-13

CARBURETOR HOSE ROUTING ......................................................... 9-16

FRONT BRAKE HOSE ROUTING ........................................................ 9-17

REAR BRAKE BREATHER HOSE ROUTING ...................................... 9-18

FUEL HOSE ROUTING ......................................................................... 9-19

REAR BRAKE CAM LEVER SET-UP .......................................................... 9-20

STEERING HEAD COVER SET-UP ............................................................. 9-21

TAILLIGHT SET-UP ...................................................................................... 9-22

SPECIAL TOOLS .......................................................................................... 9-23

TIGHTENING TORQUE ................................................................................ 9-26

ENGINE .................................................................................................. 9-26

DRIVE TRAIN ........................................................................................ 9-27

CHASSIS ............................................................................................... 9-27

PartShark.com

9

9-2 SERVICING INFORMATION

TROUBLESHOOTING

ENGINE

Complaint

Engine will not start or is hard to start.

Engine stalls easily.

Engine is noisy.

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. Slow cranking starter motor.

6. Mistimed valves.

7. Valve clearance out of adjustment.

Spark plug not sparking

1. Fouled spark plug.

2. Wet spark plug.

3. Defective ignition coil.

4. Open or short in high-tension cord.

5. Defective generator.

6. Defective CDI unit.

2. Worn cam chain sprocket.

3. Improperly working cam chain tension adjuster.

Noise seems to come from the clutch

1. Worn splines of crankshaft or inner race.

2. Worn splines of countershaft or hub.

3. Worn teeth of clutch plates.

4. Distorted clutch plates, driven and drive.

5. Clutch dampers weakened.

Replace.

Replace.

Replace.

Replace.

Replace.

Remedy

Replace.

Replace.

Repair or replace.

Tighten.

See electrical section.

Adjust.

Adjust.

Clean or replace.

Clean and dry or replace.

Replace.

Replace.

Replace.

Replace.

No fuel reaching the carburetor

1. Clogged fuel tank vent hose.

2. Clogged or defective fuel valve.

3. Defective carburetor needle valve.

4. Clogged fuel hose.

5. Clogged fuel filter.

1. Fouled spark plug.

2. Defective generator.

3. Defective CDI unit.

4. Clogged or defective fuel valve.

5. Clogged carburetor jet.

6. Valve clearance out of adjustment.

Clean or replace.

Clean or replace.

Replace.

Clean or replace.

Clean or replace.

Clean or replace.

Replace.

Replace.

Clean or replace.

Clean.

Adjust.

Excessive valve chatter

Adjust.

Replace.

3. Worn rocker arm and rocker arm shaft.

Noise seems to come from the piston

1. Worn piston.

877-999-5686

4. Worn piston pin or piston pin bore.

5. Worn piston ring or ring groove.

Replace.

Replace.

Replace.

Clean.

Replace.

Replace.

Noise seems to come from the cam chain

1. Stretched cam chain.

Replace cam chain and sprockets.

Replace cam chain and sprockets.

Repair or replace.

SERVICING INFORMATION 9-3

Complaint

Engine is noisy.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Remedy Symptom and possible causes

Noise seems to come from the crankshaft

1. Worn or burnt bearing.

2. Big-end bearing worn or burnt.

3. Excessive thrust clearance.

Noise seems to come from transmission

1. Gears worn or rubbing.

2. Badly worn splines.

3. Primary gears worn or rubbing.

4. Badly worn bearings.

5. Worn bushing.

Noise seems to come from transfer

1. Worn down gears or shafts.

2. Damage to bearings/bushing.

Replace.

Replace.

Slipping clutch.

Noise seems to come from secondary bevel gear and rear drive bevel gear

1. Drive and driven bevel gears damaged or worn.

2. Excessive backlash.

3. Improper tooth contact.

4. Damage to bearing.

5. Gears worn or rubbing.

6. Badly worn splines.

7. Secondary bevel gear thrust clearance too large.

8. Rear drive bevel gear thrust clearance too large.

1. Clutch control out of adjustment or loss of play.

2. Weakened clutch springs.

3. Worn clutch shoes.

4. Worn or distorted pressure plate.

5. Distorted clutch plates, driven and drive.

Replace.

Adjust.

Adjust.

Replace.

Replace.

Replace

Adjust or replace.

Adjust or replace.

Adjust.

Replace.

Replace.

Replace.

Replace.

Dragging clutch.

1. Clutch control out of adjustment or too much play.

Adjust.

2. Some clutch springs weakened while others are not.

Replace.

Transmission will not shift.

3. Distorted pressure plate or clutch plates.

4. Worn or damage clutch release mechanism.

1. Broken gearshift cam.

2. Distorted gearshift forks.

3. Worn gearshift shaft.

4. Worn or damage clutch release mechanism.

5. Improperly adjusted reverse cable.

Replace.

Adjust or replace.

Replace.

Replace.

877-999-5686

1. Broken reverse shift cam.

2. Shift shafts are rubbing or sticky.

Replace.

Repair

Transmission will not shift back.

3. Distorted or worn gearshift forks.

Replace.

4. Broken or damaged gearshift lever return spring.

Replace.

Transmission jumps out of gear.

Transfer will not shift or shift back.

1. Worn shifting gears on driveshaft or countershaft.

2. Distorted or worn gearshift forks.

3. Weakened cam stopper spring on gearshift cam.

4. Worn gearshift lever stopper pin.

1. Broken or worn sliding dog.

2. Broken or worn gearshift fork.

3. Worn gearshift cam.

4. Weakened cam stopper spring.

5. Worn gearshift fork shaft.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

9-4 SERVICING INFORMATION

Complaint

Engine idles poorly.

Engine runs poorly in high speed range.

Dirty or heavy exhaust smoke.

Symptom and possible causes

1. Valve clearance out of adjustment.

2. Poor seating of valves.

3. Defective valve guides.

4. Worn rocker arm or arm shaft.

5. Defective generator.

6. Defective CDI unit.

7. Spark plug gap too wide.

8. Defective ignition coil resulting in weak sparking.

9. Float-chamber fuel level out of adjustment in carburetor.

10. Clogged jets.

11. Defective fuel valve.

12. Improperly set pilot screw.

1. Valve springs wakened.

2. Valve timing out of adjustment.

3. Worn cams or rocker arms.

4. Spark plug gap too narrow.

5. Defective ignition coil.

6. Float-chamber fuel level tool low.

7. Clogged air cleaner element.

8. Clogged fuel pipe, resulting in inadequate fuel supply to carburetor.

9. Defective fuel valve.

1. Too much engine oil in the engine.

Remedy

Adjust.

Replace.

Replace.

Replace.

Replace.

Replace.

Adjust or replace.

Replace.

Adjust.

Clean.

Replace.

Adjust.

Replace.

Adjust.

Replace.

Adjust.

Replace.

Adjust.

Clean.

Clean and prime.

2. Worn piston rings or cylinder.

3. Worn valve guides.

4. Cylinder wall scored or scuffed.

5. Worn valve stems.

6. Defective stem seals.

Replace.

Check with inspection window, drain out excess oil.

Replace.

Replace.

Replace.

Replace.

Replace.

Engine lacks power.

Engine overheats.

Adjust.

Replace.

1. Loss of valve clearance.

2. Weakened valve springs.

3. Valve timing out of adjustment.

4. Worn piston ring or cylinder.

PartShark.com

8. Spark plug gap incorrect.

9. Clogged jets in carburetor.

10. Float-chamber fuel level out of adjustment.

11. Clogged air cleaner element.

Adjust.

Replace.

Repair.

Clean or replace.

Replace.

Adjust or replace.

Clean.

Adjust.

Clean.

12. Too much engine oil.

13. Sucking air around intake pipe.

Drain out excess oil.

Retighten or replace.

1. Heavy carbon deposit on piston crown.

2. Not enough oil in the engine.

3. Defective oil pump or clogged oil circuit.

4. Fuel level too low in float chamber.

5. Air leak from intake pipe.

6. Use of incorrect engine oil.

Clean.

Add oil.

Replace or clean.

Adjust.

Retighten or replace.

Change.

SERVICING INFORMATION 9-5

DRIVE TRAIN

Complaint

Power will not transmit from the engine to the rear wheel.

Symptom and possible causes

1. Broken drive and driven bevel gear teeth.

2. Broken propeller shaft serration.

3. Worn or broken rear axle serration.

4. Worn or damaged coupling joint serration.

5. Broken or damaged rear drive and driven bevel gears.

6. Worn or damaged universal joint.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Remedy

CARBURETOR

Complaint

Starting difficulty.

Idling or low-speed trouble.

Medium-or high speed trouble.

Symptom and possible causes

1. Clogged starter jet.

2. Clogged starter jet passage.

3. Air leaking from joint between starter body and carburetor.

4. Improperly working starter (enricher) plunger.

1. Clogged or loose pilot jet.

2. Clogged pilot jet passage.

3. Clogged pilot outlet port.

4. Clogged bypass port.

5. Starter (enricher) plunger not fully closed.

6. Improperly set pilot screw.

7. Incorrect float height.

1. Clogged main jet.

2. Clogged main air jet.

3. Clogged needle jet.

4. Improperly working throttle valve.

5. Clogged fuel filter.

6. Incorrect float height.

7. Starter (enricher) plunger not fully closed.

Remedy

Clean.

Clean.

Tighten, adjust or replace gasket.

Adjust.

Clean or tighten.

Clean.

Clean.

Clean.

Adjust.

Adjust.

Adjust.

Clean.

Clean.

Clean.

Adjust.

Clean or replace.

Adjust.

Adjust.

Overflow and fuel

1. Worn or damaged needle valve.

Replace.

level fluctuations.

2. Broken needle valve spring.

4. Foreign matter on the needle valve.

Replace.

PartShark.com

9-6 SERVICING INFORMATION

CHASSIS

Complaint Symptom and possible causes Remedy

Handling is too heavy or stiff.

Steering wobbles.

Steering pulls to one side.

Shocks felt in the steering.

Tires rapidly or unevenly wear.

Steering too noisy.

Suspension too soft.

1. Improper front wheel alignment.

2. Insufficiently lubricated.

3. Low air pressure in front tires.

4. Tie rod ends tending to seize.

5. Linkage connections tending to seize.

1. Unequally inflated tires.

2. Loose front wheel hub nuts.

3. Damaged or worn front wheel hub bearings.

4. Worn or loose tie rod ends.

5. Defective or incorrect front tires.

6. Damaged or worn wishbone arms and related bushings.

7. Distorted front wheels.

8. Loose chassis nuts and bolts.

Adjust.

Lubricate.

Adjust.

Replace.

Repair or replace.

Regulate.

Tighten.

Replace.

Replace or tighten.

Replace.

Replace.

1. Unequally inflated tires.

2. Improper front wheel alignment.

3. Worn front wheel hub bearings.

4. Distorted frame or wishbone.

5. Defective shock absorber.

1. High tire pressure.

2. Worn steering linkage connections.

3. Loose suspension system bolts.

1. Worn or loose front wheel hub bearings.

2. Improper front wheel alignment.

1. Loose nuts and bolts.

2. Damaged or worn front wheel hub bearings.

3. Insufficiently lubricated.

1. Weakened spring.

2. Shock absorber leaks oil.

Replace.

Tighten.

Regulate.

Adjust.

Replace.

Repair or replace.

Replace.

Regulate.

Replace.

Tighten.

Replace.

Adjust.

Tighten.

Replace.

Lubricate.

Replace.

Replace.

Suspension too stiff.

1. Worn upper or lower wishbone arms and related bush-

Suspension too noisy.

Rear wheels wobble.

ings.

1. Loose suspension system bolts.

877-999-5686

2. Damage or worn rear brake panel bearings.

3. Defective or incorrect rear tires.

Tighten.

PartShark.com

Replace.

Replace.

Replace.

4. Loose rear wheel hub nuts.

5. Distorted rear axle.

6. Loosen rear axle housing mounting bolts.

7. Improper rear brake adjustment.

8. Damaged or worn rear swingarm and related bushings.

9. Rear shock absorber leaks oil.

10. Loose rear swingarm nut.

Tighten.

Replace.

Tighten.

Adjust.

Replace.

Replace.

Tighten.

SERVICING INFORMATION 9-7

BRAKES

Complaint

Poor braking.

(FRONT)

Poor braking.

(REAR)

Insufficient brake power.

Brake squeaks.

Brake fluid leakage.

Symptom and possible causes

1. Insufficient brake fluid.

2. Air in brake fluid circuit.

3. Worn pads.

4. Worn disc.

1. Worn shoe linings.

2. Too much play on brake pedal or brake lever.

1. Leakage of brake fluid from hydraulic system.

2. Worn pads, worn lining.

3. Oil adhesion on engaging surface of pads.

4. Worn disc or bake drum.

5. Air in hydraulic system.

1. Carbon adhesion on pad surface.

Carbon adhesion on lining surface.

2. Titled pad.

3. Loose front wheel axle or rear wheel axle.

4. Worn brake pads and linings.

5. Foreign material in brake fluid.

6. Clogged return port of master cylinder.

Excessive brake lever stroke.

7. Wrongly fixed spring.

8. Caliper binding on caliper axles.

1. Air in hydraulic system.

2. Insufficient brake fluid.

3. Improper quality of brake fluid.

1. Insufficient tightening of connection joints.

2. Cracked hose.

3. Worn piston and/or cup.

Remedy

Refill to level mark.

Bleed air out.

Replace.

Replace.

Replace.

Adjust.

Repair or replace.

Replace.

Clean disc and pads.

Replace.

Bleed.

Repair surface with emery paper.

Modify pad fitting or replace.

Tighten to specified torque.

Replace.

Replace brake fluid.

Disassemble and clean master cylinder.

Set correctly.

Clean and lubricate.

Bleed.

Replenish fluid to specified level and bleed air.

Replace with correct fluid.

Tighten to specified torque and add brake fluid.

Replace.

Replace piston and/or cup.

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 specification.

Generator overcharges.

Unstable charging.

Starter button does not work.

Symptom and possible causes Remedy

1. Defective ignition coil.

2. Defective spark plug.

3. Defective generator.

4. Defective CDI unit.

5. Defective pickup coil.

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).

Replace.

Replace.

Replace.

Replace.

Replace.

Adjust carburetor.

Adjust carburetor.

Change.

Clean or replace.

Change to standard spark plug.

1. Worn piston ring.

2. Worn piston.

3. Worn cylinder.

4. Excessive valve-stem-to-valve-guide clearance.

5. Worn valve stem oil seal.

Replace.

Replace.

Replace.

Replace.

Replace.

1. Incorrect spark plug.

2. Overheated engine.

3. Loose spark plug.

4. Excessively lean air/fuel mixture.

1. Open or short in lead wires, or loose lead connections.

Change to cold type spark plug.

Turn-up.

Tighten.

Adjust carburetor.

2. Shorted, grounded or open generator coil.

3. Shorted or punctured regulator/rectifier.

1. Lead wires tend to get shorted, open-circuited, or loosely connected at terminal.

2. Grounded or open-circuited stator coils or generator.

3. Defective regulator/rectifier.

Repair, replace or connect properly.

Replace.

Replace.

Repair or tighten.

Replace.

Replace.

1. Internal short-circuit in the battery.

2. Damaged or defective 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.

Replace battery.

Replace.

Repair or replace.

877-999-5686

3. Brushes do not seat properly on the commutator in the

Replace.

Repair or replace.

starter motor.

Replace.

4. Defective starter relay.

5. Defective neutral relay.

Replace.

6. Defective emergency switch. (E-17)

7. Defective engine stop switch.

8. Defective neutral switch.

9. Defective parking brake switch.

10. Wiring connections loose or disconnected.

Replace.

Replace.

Replace.

Replace.

Connect, tighten or repair.

SERVICING INFORMATION 9-9

BATTERY

Complaint

Sulfation or spots on surfaces of cell plates.

Battery runs down quickly.

Reversed battery polarity.

Battery discharged too rapidly.

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.

2. Battery cell plates have lost much of their active material as a result of overcharging.

3. Internally shorted battery.

4. Old battery.

1. Improperly connected battery leads.

(i.e.,

-

to

+

and

+

to

-

)

1. Dirty container top and sides.

2. Old battery.

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.

Clean.

Replace.

Replace.

Remedy

Check the generator, and regulator/rectifier circuit connections, and make necessary adjustments to obtain specified charging operation.

Replace the battery and correct the charging system.

Replace.

Replace.

Replace the battery and be sure to connect it properly.

Replace the battery if badly sulfated.

9-10 SERVICING INFORMATION

WIRING DIAGRAM

B/Y B/Y

W W

Bl/R Bl/R

Bl/B Bl/B

W/Bl W/Bl

B/W B/W

G/W G/W

B/R B/R

B/W B/W B/W B/W

R

R

R

R

B/W B/W

R R

Y/B Y/B

B/W B/W

R R

B B

B B

B B

B/Y B/Y

B B

B B

B B

G/W G/Y

B/Y B/Y

Y Y

Y Y

Y Y

G/W G/W

W/Bl W/Bl

B/W B/W

W/B W/B

O O

W W

O O

Y/B Y/B

O O

B/G B/G

B/Bl B/Bl

Bl/R

O/Bl

Bl/B

O/W O/W

Gr Gr

O O

W W

Y Y

Y/G Y/G

B/Bl B/Bl

Bl/B Bl/B

Bl Bl

PartShark.com

B/Y

B/Bl

B/Br

B

B/R

B/G

Bl/R

W

B/W

B/W

B/Bl B/Bl

B/W

R

Bl

877-999-5686

B

B/O

B

B

B

W/B W/B

B B

B/O B/O

B B

B/O B/O

B B

Bl

O

Bl/R

O

Bl

Bl/R

O O

R R

Gr Gr

O O

R R

Gr Gr

SERVICING INFORMATION 9-11

WIRING HARNESS, CABLE, AND HOSE ROUTING

WIRING HARNESS ROUTING

Ignition coil

EC approval label

(E-28)

Wiring harness

Handlebar switch

Ignition swich

Reverse cable

Brake light/Taillight

Wiring harness

Battery

+

Clamp

Clamp

Clamp

Parking brake

Pilot lamp

Left brake switch

Clamp

Clamp

Wiring harness

Set the generator coupler inside of the frame.

Clamp

Wiring harness

Neutral relay

Regulator/rectifier

Starter relay

IECS label (E-28)

Starter motor

PartShark.com

Generator

Battery

after clamping the several lead wire.

Cut the tip of the clamp after clamping the pedal switch lead wire.

Starter motor

Clamp

Neutral switch

Brake pedal switch

Clamp

Brake light pedal switch

9-12 SERVICING INFORMATION

Handlebar switch (L)

Parking brake switch

Brake lever switch

Starter cable

Set the coupler inside.

Clamp

Forward

Pass the lead wire on the upper bracket.

30ß

10ß

Front brake switch

Clamp

Neutral switch lead wire

Rear brake lamp switch harness

VIEW A

Clamp

Generator lead wire

Battery

-

Ignition switch

Starter motor lead wire

VIEW B

Grommet

Carburetor drain hose

Clamp

Magneto cover

B

Neutral switch lead wire

Clamp

7 NÆm (0.7 kgf-m, 5.0 lb-ft)

PartShark.com

C

Starter motor lead wire

877-999-5686

6 NÆm

Starter motor

VIEW C

Starter motor

SERVICING INFORMATION 9-13

CABLE ROUTING

Throttle cable

Parking brake cable

Clamp

Reverse cable

Throttle cable

Brake hose

Reverse cable

Pass the throttle cable in front of the parking brake cable.

DETAIL E

E

Starter cable

Cable guide

FRONT

Parking brake cable

Pass the parking brake cable behind the brake hose.

Clamp

Starter cablle

Pass the reverse cable in front of the brake pipe.

DETAIL A

Brake cable adjuster

Brake cable pin

Make sure that the small-pitch portion of the cable spring faces to the pin.

Rear brake cable spring

FRONT

Pass the throttle cable between the brake hose and handlebars.

Clamp

Pass the parking and throttle cables under the frame.

D

Parking brake cable

Throttle cable

Clamp

Rear brake cable

A

Pass the parking brake cable under the rear brake cable.

877-999-5686

Rear brake cable

Pass the parking brake cable

Pass the parking brake cable

C

through the frame bracket.

Clamp

Pass the throttle cable inside of the frame.

Clamp the parking cable with the throttle cable.

Clamp

Parking brake

Rear brake cable

OUTSIDE cable inside of the

B

rear brake cable.

Set the pin inside.

Fix the rubber of the parking brake cable with the cable guide.

FRONT

Throttle cable

Pass the parking brake cable outside of the frame.

Brake cable pin

OUTSIDE

Pass the parking cable and throttle cable under the frame.

DETAIL D

Parking brake cable

DETAIL B DETAIL C

FRONT

9-14 SERVICING INFORMATION

Parking brake cable

Reverse cable

Clamp

Do not give too much play.

Clamp the starter cable with the wiring harness.

Clamp the starter cable inside of the frame.

Starter cable

Wiring harness

OUTSIDE

Clamp

FRONT

DETAIL F

Starter cable

Pass the starter cable under the frame.

F

Clamp

G

Reverse cable pin

Set the pin outside

Reverse cable

DETAIL G

STEERING SHAFT SET-UP

SERVICING INFORMATION 9-15

Tighten the rear bolts after tightening the front ones.

Clearance

9-16 SERVICING INFORMATION

CARBURETOR HOSE ROUTING

Left Right

45ß

Left Right

Air vent hose

Carburetor

877-999-5686

Clamp

Clamp

FRONT BRAKE HOSE ROUTING

SERVICING INFORMATION 9-17

9-18 SERVICING INFORMATION

REAR BRAKE BREATHER HOSE ROUTING

FUEL HOSE ROUTING

SERVICING INFORMATION 9-19

9-20 SERVICING INFORMATION

REAR BRAKE CAM LEVER SET-UP

SERVICING INFORMATION 9-21

STEERING HEAD COVER SET-UP

Fuel tank breather hose No. 2

Steering head cover bracket

Steering head cover

Clip

9-22 SERVICING INFORMATION

TAILLIGHT SET-UP

Rear fender

Side reflector

E-28 ONLY

Rear reflector

Taillight

SERVICING INFORMATION 9-23

SPECIAL TOOLS

09900-00410

Hexagon wrench set

09900-06106

Snap ring pliers

09900-06107

Snap ring pliers

09900-06108

Snap ring pliers

09900-09004

Impact driver set

09900-20101

Vernier calipers

09900-20202

Micrometer

(1/100 mm,

25 50 mm)

09900-20203

Micrometer

(1/100 mm,

50 75 mm)

09900-20205

Micrometer

(1/1000 mm,

0 25 m m)

09900-20508

Cylinder gauge set

(1/100 mm,

40 80 mm)

09900-20605

09900-20602

Dial gauge

(1/1000 mm)

09900-20804

Tickness gauge

Dial calipers

(1/100 mm,

09900-20607

Dial gauge 09900-20701 09900-20803

Tickness gauge 10 34 mm) (1/100 mm) Magnetic stand

PartShark.com

09900-21304 09900-22401

09900-20805

Tire depth gauge

V-block set

(100 mm)

09900-22302

Plastigauge

Small bore gauge

(10 18 mm)

09900-25008

Multi circuit tester set

09900-26006

Tachometer

09910-32812

Crankshaft installer

09913-50121

Oil seal remover

09913-70210

Bearing installer set

9-24 SERVICING INFORMATION

09913-85210

Bearing/oil seal installer

09915-64510

Compression gauge set

09918-02410 or

09918-03810

(Adaptor)

09915-74511

Oil pressure gauge

09915-74512

Oil pressure gauge adaptor

09916-10911

Valve lapper set

09916-14510

Valve spring compressor

09916-14910

Valve spring compressor attachment

09916-21111

09916-24900

Valve seat cutter set

09916-24450

Solid pilot

(N-100-5.52)

09916-22480

Solid pilot

(N-140-5.5)

09916-24935

Valve seat cutter

(N-608)

09916-34550 09916-34561 09916-44910

09916-34542

Reamer handle

Valve guide reamer

(5.5 mm)

Valve guide reamer

(11.3 mm)

Valve guide remover/installer

877-999-5686

09920-13120

Crankcase separator

09920-53730

Clutch sleeve hub holder

09921-20210

Bearing puller

09921-20240

Bearing remover set

09916-84511

Tweezers

09921-21820

Bearing locknut wrench

09921-21910

Bearing holder

09923-74510

Bearing remover

09924-84510

Bearing installer set

09930-30104

Sliding shaft

SERVICING INFORMATION 9-25

09930-10121

Spark plug wrench set

09930-30721

Rotor remover

09930-35010

Rotor remover

09930-31921

Rotor remover

09930-44520

Rotor holder

09930-73150

Output shaft holder

09950-81910

Remover

NOTE:

When ordering a special tool, please confirm whether it is available or not.

9-26 SERVICING INFORMATION

TIGHTENING TORQUE

ENGINE

Cylinder head cover bolt

Camshaft sprocket bolt

ITEM

Cylinder head nut (M8)

Cylinder head nut (M6)

Cylinder base nut (M6)

Cam chain tensioner mounting bolt

Cam chain tension adjuster spring holder bolt

Neutral switch bolt

Spark plug

Rocker arm shaft bolt

Valve clearance adjuster locknut

Crankcase bolt

Valve timing inspection plug

Clutch shoe nut

14

11

23

140

8

7

18

9

N•m

10

11

23

10

10

10

Clutch sleeve hub nut

Clutch adjuster lock nut

Clutch adjuster cap

Generator rotor nut

Generator cover cap

Starter clutch bolt

Exhaust pipe nut

Muffler mounting bolt/nut

100

23

15

160

15

26

23

23

Muffler connecting bolt

Spark arrester bolt

23

11

2.3

1.1

Engine oil drain plug

Secondary drive bevel gear nut

Secondary driven bevel gear nut

Engine mounting bolt/nut

Engine mounting bracket bolt

21

100

2.1

10.0

100

66

23

10.0

2.3

Starter motor lead wire nut 6 0.6

Starter motor mounting bolt 10 1.0

1.0

2.3

1.5

16.0

1.5

2.6

2.3

2.3

0.8

0.7

1.8

0.9

1.4

1.1

2.3

14.0

kgf-m

1.0

1.1

2.3

1.0

1.0

1.0

16.5

8.0

15.0

72.5

72.5

48.0

16.5

4.5

7.0

72.5

16.5

11.0

115.5

11.0

19.0

16.5

16.5

6.0

5.0

13.0

6.5

10.0

8.0

16.5

101.5

lb-ft

7.0

8.0

16.5

7.0

7.0

7.0

SERVICING INFORMATION 9-27

DRIVE TRAIN

ITEM

Final gear case cover bolt

Pinion gear bearing locknut

Rear drive gear oil filler plug

Rear drive gear oil drain plug

Rear axle housing set bolt/nut (RH)

Rear axle housing set bolt/nut (LH)

Rear axle housing/final gear case bolt

N•m

26

100

26

26

60

65

65

kgf-m

2.6

10.0

2.6

2.6

6.0

6.5

6.5

CHASSIS

Handlebar clamp bolt

Steering shaft holder bolt

Steering shaft nut

ITEM

Wishbone arm pivot bolt/nut (upper and lower)

Wheel hub nut (front)

Wheel hub nut (rear)

Wheel set nut (front and rear)

Steering knuckle nut (upper and lower)

Front shock absorber mounting bolt/nut (upper and lower)

Tie rod end nut

Tie rod lock nut

Front brake air bleeder valve

N•m

23

23

49

65

65

138

50

29

60 6.0

29

29

6.0

2.9

2.9

0.6

Front brake caliper mounting bolt 26 2.6

Front brake pipe nut (Upper and lower) 16 1.6

Front brake pad mounting pin

Front brake caliper holder pin

Front brake caliper holder slide pin

Front brake master cylinder mounting bolt

Front brake hose union bolt

Front brake disc bolt

18

18

23

10

23

23

1.8

1.8

2.3

1.0

2.3

2.3

kgf-m

2.3

2.3

4.9

6.5

6.5

13.8

5.0

2.9

Front brake disc plate mounting bolt

Footrest bolt (M8)

Footrest bolt (M10)

Rear shock absorber mounting bolt/nut (Upper)

Rear shock absorber mounting bolt/nut (Lower)

Swingarm pivot bolt/nut

Rear brake cam lever bolt/nut

Rear brake pedal mounting bolt

Rear brake panel mounting nut

60

85

11

11

60

23

26

55

78

6.0

8.5

1.1

1.0

6.0

2.3

2.6

5.5

7.8

lb-ft

19.0

72.5

19.0

19.0

43.5

47.0

47.0

lb-ft

16.5

16.5

35.5

47.0

47.0

99.9

36.0

21.0

43.5

16.5

7.0

16.5

16.5

16.5

19.0

40.0

55.0

43.5

61.5

8.0

8.0

43.5

21.0

21.0

4.4

19.0

11.6

13.0

13.0

9-28 SERVICING INFORMATION

TIGHTENING TORQUE CHART

For other nuts and bolts not listed in the preceding page, refer to this chart:

Bolt Diameter

A

(mm)

4

5

6

8

10

12

14

16

18

Conventional or 4 marked bolt

N•m

1.5

kgf-m

0.15

lb-ft

1.0

3

5.5

13

29

0.3

0.55

1.3

2.9

2.0

4.0

9.5

21.0

45

65

105

160

4.5

6.5

10.5

16.0

32.5

47.0

76.0

115.5

N•m

2.3

4.5

10

23

50

85

135

210

240

7 marked bolt kgf-m

0.23

0.45

1.0

2.3

5.0

8.5

13.5

21.0

24.0

lb-ft

1.5

3.0

7.0

16.5

36.0

61.5

97.5

152.0

173.5

A

Conventional bolt

4 marked bolt

7 marked bolt

SERVICING INFORMATION 9-29

SERVICE DATA

VALVE + GUIDE

ITEM

Valve diam.

Tappet clearance (when cold)

Valve guide to valve stem clearance

IN.

EX.

IN.

EX.

IN.

EX.

STANDARD

32

(1.3)

28

(1.1)

0.03 0 .08

(0.001 0 .003)

0.08 0 .13

(0.003 0 .005)

0.010 0 .037

(0.0004 0 .0015)

0.030 0 .057

(0.0012 0 .0024)

Valve stem deflection

IN. & EX.

Valve guide I.D.

Valve stem O.D.

IN. & EX.

IN.

EX.

5.500 5 .512

(0.2165 0 .2170)

5.475 5 .490

(0.2156 0 .2161)

5.455 5 .470

(0.2148 0 .2154)

Valve stem runout

IN. & EX.

Valve head thickness

IN. & EX.

Valve stem end length

IN. & EX.

Valve seat width

Valve head radial runout

Valve spring free length

IN. & EX.

IN. & EX.

877-999-5686

IN. & EX.

0.88 1 .08

(0.035 0 .043)

PartShark.com

Valve spring tension 256 2 94 N

(26.1 3 0.0 kgf, 57.5 66 .1 lbs) at length 36.6 mm (1.44 in)

Unit: mm (in)

LIMIT

0.35

(0.014)

0.05

(0.002)

0.5

(0.02)

2.5

(0.10)

0.03

(0.001)

43.0

(1.69)

9-30 SERVICING INFORMATION

CAMSHAFT + CYLINDER HEAD

ITEM

Cam height

IN.

Camshaft journal oil clearance

Camshaft journal holder I.D.

Camshaft journal O.D.

EX.

STANDARD

33.780 33.820

(1.3299 1.3315)

32.990 33.030

(1.2988 1.3004)

0.036 0.066

(0.0014 0.0026)

22.012 22.025

(0.8666 0.8671)

21.959 21.976

(0.8645 0.8652)

Unit: mm (in)

LIMIT

33.480

(1.3181)

32.690

(1.2870)

0.150

(0.0059)

Camshaft runout 0.10

(0.004)

Rocker arm I.D.

Rocker arm shaft O.D.

IN. & EX.

IN. & EX.

12.000 12.018

(0.4724 0.4731)

11.977 11.995

(0.4715 0.4722)

Cylinder head distortion

Cylinder head cover distortion

0.05

(0.002)

0.05

(0.002)

Unit: mm (in)

CYLINDER + PISTON + PISTON RING

ITEM

Compression pressure

STANDARD

1 400 kPa

(14.0 kgf/cm 2 , 199 psi)

Piston to cylinder clearance

LIMIT

1 200 kPa

(12.0 kgf/cm

2

,

171 psi)

0.120

(0.0047)

0.040 0. 050

(0.0016 0. 0020)

Cylinder bore 66.090

(2.6020)

66.000 66. 015

(2.5984 2. 5990)

Piston diam.

65.955 65. 970

65.880

(2.5937)

Cylinder distortion

Piston ring free end gap

1st R

(2.5966 2. 5972)

Measure at 18 mm (0.71 in) from the skirt end.

877-999-5686

1st

0.10 0. 25

0.05

(0.002)

7.0

(0.28)

7.2

(0.28)

0.50

Piston ring end gap

(0.004 0. 010) (0.020)

0.10 0. 25

(0.004 0. 010)

Piston ring to groove clearance

2nd

1st

0.5

(0.020)

0.180

(0.007)

0.150

(0.006)

2nd

Piston ring groove width

1st

2nd

1.01 1. 03

(0.0398 0. 0406)

1.21 1. 23

(0.0476 0. 0484)

2.01 2. 03

(0.0791 0. 0799)

Oil

SERVICING INFORMATION 9-31

ITEM

Piston ring thickness

Piston pin bore

Piston pin O.D.

1st

2nd

LIMIT STANDARD

0.97 0.99

(0.038 0.039)

1.17 1.19

(0.046 0.047)

16.002 16.008

(0.6300 0.6302)

15.992 16.000

(0.6296 0.6299)

16.030

(0.6311)

15.980

(0.6291)

CONROD + CRANKSHAFT

ITEM

Conrod small end I.D.

Conrod deflection

STANDARD

16.006 16 .014

(0.6302 0.6305)

Unit: mm (in)

LIMIT

16.040

(0.6315)

3.0

(0.12)

1.0

(0.04)

Conrod big end side clearance

Conrod big end width

Crank web to web width

0.10 0. 45

(0.004 0.018)

17.95 18 .00

(0.707 0.709)

53.0 – 0.1

(2.087 – 0.004)

Crankshaft runout 0.08

(0.003)

OIL PUMP

ITEM

Oil pressure (at 60 C, 140 F)

LIMIT STANDARD

Above 30 kPa (0.3 kgf/cm 2 , 4.3 psi)

Below 70 kPa (0.7 kgf/cm

2

, 9.9 psi) at 3 000 r/min.

CLUTCH

Clutch release screw

Drive plate thickness

Drive plate claw width

Driven plate distortion

Clutch spring free length

Clutch wheel I.D.

Clutch shoe

Clutch engagement r/min.

Clutch lock-up r/min.

Unit: mm (in)

LIMIT STANDARD

1/16 1 /8 turn back

877-999-5686

(0.469 0.472)

28.9

(1.14)

116.00 1 16.15

(4.567 4.573)

2.4

(0.094)

11.0

(0.433)

0.10

(0.004)

27.5

(1.08)

116.5

(4.59)

No groove at any part

1 700 2 100 r/min

3 100 3 700 r/min

9-32 SERVICING INFORMATION

DRIVE TRAIN

ITEM

Primary reduction ratio

Secondary reduction ratio

Final reduction ratio

Gear ratios 1st

2nd

3rd

4th

5th

Reverse

Shift fork to groove clearance

Shift fork groove width

Shift fork thickness

Gearshift lever height

Secondary bevel gear backlash

Rear drive (final) bevel gear backlash

STANDARD

3.047 (64/21)

1.133 (17/15)

3.200 (32/10)

3.083 (37/12)

1.933 (29/15)

1.388 (25/18)

1.095 (23/21)

0.913 (21/23)

2.833 (34/12)

0.10 0.30

(0.004 0.012)

4.50 4.6 0

(0.169 0.173)

4.30 4.40

(0.169 0.173)

0 10

(0 0 .393)

0.03 0.15

(0.001 0.006)

0.05 0.30

(0.002 0.012)

Unit: mm (in) Except ratio

LIMIT

CARBRETOR

Carburetor type

Bore size

I.D. No.

Idle r/min

Float height

Main jet

Jet needle

SPECIFICATION

ITEM

E-19, 28

MIKUNI BSR29

E-33

←

29 mm

(1.14 in)

PartShark.com

←

(M.J.)

(J.N.)

1 500 – 100 r/min

13.0 – 1.0 mm

(0.51 – 0.04 in)

21G1

←

←

#125

5DH54-2nd

#

←

(N.J.) P-0M

#

Needle jet

Pilot jet (P.J.) #20

#

PRE-SET Pilot screw

Throttle cable play

(P.S.)

Starter (enricher) plunger cable play

1-1/2 turns back

3 5 mm

(0.12 0.2 0 in)

0.5 1.0 mm

(0.02 0.0 4 in)

←

←

0.5

(0.020)

SERVICING INFORMATION 9-33

ELECTRICAL

ITEM

Spark plug

Spark performance

Ignition coil resistance

Ignition coil primary peak voltage

Generator coil resistance

Type

Gap

Primary

Secondary

Pick-up

Charging

SPECIFICATION

NGK: DR7EA

DENSO: X22ESR-U

0.6 0.7

(0.024 0.028)

Over 8 (0.3) at 1 atm.

0.05 1.0

Ω

10.5 1 9.0 k

Ω

120 V and more

80 155

Ω

0.5 1. 2

Ω

4.0 V and more Pick-up coil peak voltage

Generator no-load voltage

(When engine is cold)

Generator Max. output

Regulated voltage

Starter relay resistance

Battery Type designation

Capacity

Fuse size

65 V (AC) and more at 5 000 r/min

Approx. 150 W at 5 000 r/min

14.0 15.5 V at 5 000 r/min

3 6

Ω

YTX9-BS

12V 28.8 kC (8 Ah)/10HR

20 A

WATTAGE

ITEM

Headlight HI

LO

SPECIFICATION

40

40

Brake light/Taillight

Reverse indicator light

Neutral indicator light

21/5

3

877-999-5686

Unit: mm (in)

NOTE

Terminal

Terminal

Plug cap

Terminal

+

: B/W

-

: W/Bl

Bl/Y G/W

Y Y

+

: G/W

-

: Bl/Y

Unit: W

9-34 SERVICING INFORMATION

Unit: mm (in)

BRAKE + WHEEL

ITEM

Rear brake lever play

Rear brake pedal free travel

LIMIT STANDARD/SPECIFICATION

3 5

(0.12 0.20)

20 30

(0.79 1.18)

2.8 3.2

(0.110 0.126)

Brake disc thickness

Brake disc runout

Brake drum I.D.

Front

Front

Rear

2.5

(0.098)

0.30

(0.012)

140.7

(5.54)

Master cylinder bore

Master cylinder piston diam.

Front

Front

12.700 12.743

(0.5000 0.5017)

12.657 12.684

(0.4983 0.4994)

Brake caliper cylinder bore

Brake caliper piston diam.

Front

Front

32.030 32.080

(1.2610 1. 2630)

31.948 31.998

(1.2578 1.2598)

DOT 4 Brake fluid type

Turning radius

Toe-in (with 75 kg, 165 lbs)

2.7 m (8.9 ft)

5 – 4

(0.20 – 0.16)

Camber 0

Caster

Wheel rim size Front

7 40

10 5.5 A T

Tire size

Tire tread depth

Wheel axle runout

Rear 9 8.0 AT

Front

Front

AT22 7-10

✩✩

PartShark.com

Rear

4.0

(0.16)

4.0

(0.16)

3.0

(0.12)

TIRE PRESSURE

COLD INFLATION

TIRE PRESSURE

FRONT

REAR kPa

30

25

VEHICLE LOAD CAPACITY LIMIT: 110 kg (243 lbs) kgf/cm

2

0.30

0.25

psi

4.4

3.6

SERVICING INFORMATION 9-35

FUEL + OIL

Fuel type

ITEM

Fuel tank including reserve

Reserve

Engine oil type

Engine oil capacity

Final gear oil type

Final gear oil capacity

SPECIFICATION

Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) 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.

10.6 L

(2.8/2.3 US/lmp gal)

2.6 L

(0.7/0.6 US/lmp gal)

SAE 10W-40, API SF or SG

Change

Filter change

2 200 ml

(2.3/1.9 US/lmp qt)

2 300 ml

(2.4/2.0 US/lmp qt)

Overhaul

2 500 ml

(2.6/2.2 US/lmp qt)

Hypoid gear oil SAE #90, API grade GL-5

190 ml

(6.4/6.7 US/lmp oz)

NOTE

E-28, 33

The others

 

LT-Z250K5 ( 05-MODEL)

LT-Z250K5 ( 05-MODEL) 10-1

This chapter describes specifications, service data and servicing procedures which differ from those of the LT-Z250K4 ( 04-MODEL).

NOTE:

* Any differences between the LT-Z250K4 ( 04-MODEL) and LT-Z250K5 ( 05-MODEL) in specifications and service data are indicated with an asterisk mark (*).

* Please refer to the chapter 1 through 9 for details which are not given in this chapter.

CONTENTS

SPECIFICATIONS ......................................................................................... 10- 2

SERVICE DATA ............................................................................................ 10- 3

TIGHTENING TORQUE................................................................................. 10-10

FRONT BRAKE CALIPER MOUNTING BOLT ............................................. 10-10

FRONT BRAKE HOSE ROUTING ................................................................ 10-11

10

10-2 LT-Z250K5 ( 05-MODEL)

SPECIFICATIONS

DIMENSIONS AND DRY MASS

Overall length ......................................................................................

1 720 mm (67.7 in)

Overall width .......................................................................................

1 070 mm (42.1 in)

Overall height ......................................................................................

1 090 mm (42.9 in)

Wheelbase ..........................................................................................

1 135 mm (44.7 in)

Front track ...........................................................................................

830 mm (32.7 in)

Rear track............................................................................................

810 mm (31.9 in)

Ground clearance................................................................................

230 mm (9.1 in)

Seat height ..........................................................................................

810 mm (31.9 in)

Dry mass.............................................................................................

166 kg (365 lbs)

ENGINE

Type.....................................................................................................

Four-stroke, air-cooled, OHC

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

1

Bore ....................................................................................................

66.0 mm (2.598 in)

Stroke..................................................................................................

72.0 mm (2.835 in)

Displacement ......................................................................................

246 cm 3 (15.0 cu. in)

Compression ratio ...............................................................................

9.2: 1

Carburetor ...........................................................................................

MIKUNI BSR29, single

Air cleaner ...........................................................................................

Polyurethane foam element

Starter system.....................................................................................

Electric

Lubrication system ..............................................................................

Wet sump

Idle speed ...........................................................................................

1 500 – 100 r/min

DRIVE TRAIN

Clutch ..................................................................................................

Wet multi-plate, automatic, centrifugal type

Transmission .......................................................................................

5-forward and 1-reverse

Gearshift pattern, forward .................................................................

All up, foot lever operated reverse .................................................................

Foot/hand operated

Primary reduction ratio........................................................................

3.047 (64/21)

Secondary reduction ratio ...................................................................

1.133 (17/15)

Gear ratios, Low ..............................................................................

3.083 (37/12)

2nd ...............................................................................

1.933 (29/15)

3rd................................................................................

1.388 (25/18)

4th ................................................................................

1.095 (23/21)

Top ...............................................................................

0.913 (21/23)

Reverse........................................................................

2.833 (34/12)

Final reduction ratio.............................................................................

3.200 (32/10)

CHASSIS

Front suspension.................................................................................

Independent, double wishbone, coil spring, oil damped

Rear suspension .................................................................................

Swingarm type, coil spring, oil damped

Front wheel travel ................................................................................

160 mm (6.3 in)

Rear wheel travel ................................................................................

170 mm (6.7 in)

Caster .................................................................................................

7 40 .....................1G

Trail......................................................................................................

33 mm (1.30 in).....1G

Toe-in ..................................................................................................

5 mm (0.20 in).......1G

PartShark.com

Front tire size ......................................................................................

AT22 7-10



, tubeless

Rear tire size .......................................................................................

AT20 10-9



, tubeless

ELECTRICAL

877-999-5686

Ignition type.........................................................................................

Electronic ignition (CDI)

Ignition timing ......................................................................................

5 B .T.D.C. at 1 500 rpm

Spark plug...........................................................................................

NGK DR7EA or DENSO X22ESR-U

Battery.................................................................................................

12 V 28.8 kC (8 Ah)/10 HR

Generator ............................................................................................

Three-phase A.C. generator

Main fuse ............................................................................................

20/15 A

Headlight .............................................................................................

12 V 40/40 W

Brake light/Taillight ..............................................................................

12 V 21/5 W

Neutral indicator light ..........................................................................

12 V 3 W

Reverse indicator light.........................................................................

12 V 3 W

CAPACITIES

Fuel tank, including reserve..............................................................

10.6 L (2.8/2.3 US/Imp gal) reserve .............................................................................

2.6 L (0.7/0.6 US/Imp gal)

Engine oil, oil change.........................................................................

2 200 ml (2.3/1.9 US/Imp qt) filter change .....................................................................

2 300 ml (2.4/2.0 US/Imp qt) overhaul ...........................................................................

2 500 ml (2.6/2.2 US/Imp qt)

Final gear oil change...........................................................................

190 ml (6.4/6.7 US/Imp oz)

SERVICE DATA

VALVE + GUIDE

ITEM

Valve diam.

Tappet clearance (when cold)

Valve guide to valve stem clearance

IN.

EX.

IN.

EX.

IN.

EX.

STANDARD

32

(1.3)

28

(1.1)

0.03 0.08

(0.001 0.003)

0.08 0.13

(0.003 0.005)

0.010 0.037

(0.0004 0.0015)

0.030 0.057

(0.0012 0.0024)

Valve stem deflection

IN. & EX.

Valve guide I.D.

Valve stem O.D.

IN. & EX.

IN.

EX.

5.500 5.512

(0.2165 0.2170)

5.475 5.490

(0.2156 0.2161)

5.455 5.470

(0.2148 0.2154)

Valve stem runout

IN. & EX.

Valve head thickness

IN. & EX.

Valve stem end length

IN. & EX.

Valve seat width

IN. & EX.

0.88 1.08

(0.035 0.043)

Valve head radial runout

Valve spring free length

Valve spring tension

IN. & EX.

PartShark.com

LT-Z250K5 ( 05-MODEL) 10-3

Unit: mm (in)

LIMIT

0.35

(0.014)

0.05

(0.002)

0.5

(0.02)

2.5

(0.10)

0.03

(0.001)

43.0

(1.69)

10-4 LT-Z250K5 ( 05-MODEL)

CAMSHAFT + CYLINDER HEAD

ITEM

Cam height

IN.

EX.

Camshaft journal oil clearance

Camshaft journal holder I.D.

Camshaft journal O.D.

Camshaft runout

Rocker arm I.D.

Rocker arm shaft O.D.

IN. & EX.

IN. & EX.

Cylinder head distortion

Cylinder head cover distortion

STANDARD

33.780 33.820

(1.3299 1.3315)

32.990 33.030

(1.2988 1.3004)

0.036 0.066

(0.0014 0.0026)

22.012 22.025

(0.8666 0.8671)

21.959 21.976

(0.8645 0.8652)

12.000 12.018

(0.4724 0.4731)

11.977 11.995

(0.4715 0.4722)

Unit: mm (in)

LIMIT

33.480

(1.3181)

32.690

(1.2870)

0.150

(0.0059)

0.10

(0.004)

0.05

(0.002)

0.05

(0.002)

Unit: mm (in)

CYLINDER + PISTON + PISTON RING

ITEM

Compression pressure

STANDARD

1 400 kPa

(14.0 kgf/cm 2 , 199 psi)

Piston to cylinder clearance 0.040 0.050

(0.0016 0.0020)

LIMIT

1 200 kPa

(12.0 kgf/cm

171 psi)

2 ,

0.120

(0.0047)

Cylinder bore 66.090

(2.6020)

66.000 66.015

(2.5984 2.5990)

Piston diam.

Cylinder distortion

Piston ring free end gap

65.955 65.970

(2.5966 2.5972)

PartShark.com

2nd R

Approx. 8.7 (0.34)

Approx. 9.0 (0.35)

0.10 0.25

65.880

(2.5937)

0.05

(0.002)

7.0

(0.28)

7.2

(0.28)

0.50

(0.020)

Piston ring end gap

1st

(0.004 0.010)

0.10 0.25

(0.004 0.010)

Piston ring to groove clearance

2nd

1st

0.5

(0.020)

0.180

(0.007)

0.150

(0.006)

2nd

LT-Z250K5 ( 05-MODEL) 10-5

CONROD + CRANKSHAFT

ITEM

Conrod small end I.D.

Conrod deflection

Conrod big end side clearance

Conrod big end width

Crank web to web width

Crankshaft runout

STANDARD

16.006 16.014

(0.6302 0.6305)

0.10 0.45

(0.004 0.018)

17.95 18.00

(0.707 0.709)

53.0 – 0.1

(2.087 – 0.004)

Unit: mm (in)

LIMIT

16.040

(0.6315)

3.0

(0.12)

1.0

(0.04)

0.08

(0.003)

OIL PUMP

ITEM

Oil pressure (at 60 C, 140 F)

LIMIT STANDARD

Above 30 kPa (0.3 kgf/cm

2

, 4.3 psi)

Below 70 kPa (0.7 kgf/cm

2

, 9.9 psi) at 3 000 r/min

CLUTCH

ITEM

Clutch release screw

Drive plate thickness

Drive plate claw width

Driven plate distortion

STANDARD

1/16 1/8 turn back

2.7 2.9

(0.106 0.114)

11.9 12.0

(0.469 0.472)

Clutch spring free length

Clutch wheel I.D.

Clutch shoe

116.00 116.15

PartShark.com

Clutch engagement r/min

Clutch lock-up r/min

28.9

(1.14)

877-999-5686

Unit: mm (in)

LIMIT

2.4

(0.094)

11.0

(0.433)

0.10

(0.004)

27.5

(1.08)

116.5

(4.59)

No groove at any part

10-6 LT-Z250K5 ( 05-MODEL)

DRIVE TRAIN

ITEM

Primary reduction ratio

Secondary reduction ratio

Final reduction ratio

Gear ratios 1st

2nd

3rd

4th

5th

Reverse

Shift fork to groove clearance

Shift fork groove width

Shift fork thickness

Gearshift lever height

Secondary bevel gear backlash

Rear drive (final) bevel gear backlash

Unit: mm (in) Except ratio

LIMIT STANDARD

3.047 (64/21)

1.133 (17/15)

3.200 (32/10)

3.083 (37/12)

1.933 (29/15)

1.388 (25/18)

1.095 (23/21)

0.913 (21/23)

2.833 (34/12)

0.10 0.30

(0.004 0.012)

4.50 4.60

(0.169 0.173)

4.30 4.40

(0.169 0.173)

0 10

(0 0.393)

0.03 0.15

(0.001 0.006)

0.05 0.30

(0.002 0.012)

CARBRETOR

Carburetor type

Bore size

I.D. No.

Idle r/min

Float height

Main jet

Jet needle

Needle jet

SPECIFICATION

ITEM

E-19, 28

MIKUNI BSR29

E-33

←

←

29 mm

(1.14 in)

(M.J.)

(J.N.)

21G0

1 500 – 100 r/min

13.0 – 1.0 mm

(0.51 – 0.04 in)

#125

5DH54-2nd

21G1

PartShark.com

#

←

←

←

(N.J.)

(P.J.)

877-999-5686

P-0M

#20

#

# Pilot jet

Pilot screw

(P.S.) 1 and 1/2 turns back PRE-SET

Throttle cable play 3 5 mm

(0.12 0.20 in)

0.5 1.0 mm

(0.02 0.04 in)

←

Starter (enricher) plunger cable play

←

0.5

(0.020)

LT-Z250K5 ( 05-MODEL) 10-7

ELECTRICAL

Spark plug

ITEM

Spark performance

Ignition coil resistance

Ignition coil primary peak voltage

Generator coil resistance

Pick-up coil peak voltage

Generator no-load voltage

(When engine is cold)

Generator Max. output

Regulated voltage

Starter relay resistance

Battery Type designation

Capacity

Fuse size

Type

Gap

Primary

SPECIFICATION

NGK: DR7EA

DENSO: X22ESR-U

0.6 0.7

(0.024 0.028)

Over 8 (0.3) at 1 atm.

0.05 1.0

Ω

Secondary

Pick-up

Charging

10.5 19.0 k

Ω

120 V and more

80 155

Ω

0.5 1.2

Ω

4.0 V and more

65 V (AC) and more at 5 000 r/min

Approx. 150 W at 5 000 r/min

14.0 15.5 V at 5 000 r/min

3 6

Ω

YTX9-BS

12V 28.8 kC (8 Ah)/10HR

20 A

WATTAGE

ITEM

Headlight HI

LO

SPECIFICATION

40

40

Brake light/Taillight 21/5

Reverse indicator light

Neutral indicator light

3

877-999-5686

Unit: mm (in)

NOTE

Terminal

Terminal

Plug cap

Terminal

+

: B/W

-

: W/Bl

Bl/Y G/W

Y Y

+

: G/W

-

: Bl/Y

Unit: W

10-8 LT-Z250K5 ( 05-MODEL)

BRAKE + WHEEL

ITEM

Rear brake lever play

Unit: mm (in)

LIMIT

Rear brake pedal free travel

STANDARD/SPECIFICATION

3 5

(0.12 0.20)

20 30

(0.79 1.18)

2.8 3.2

(0.110 0.126)

Brake disc thickness

Brake disc runout

Brake drum I.D.

Front

Front

Rear

2.5

(0.098)

0.30

(0.012)

140.7

(5.54)

Master cylinder bore

Master cylinder piston diam.

Brake caliper cylinder bore

Front

Front

Front

12.700 12.743

(0.5000 0.5017)

12.657 12.684

(0.4983 0.4994)

32.030 32.080

(1.2610 1.2630)

Brake caliper piston diam.

Brake fluid type

Turning radius

Toe-in (with 75 kg, 165 lbs)

Front

31.948 31.998

(1.2578 1.2598)

DOT 4

2.7 m (8.9 ft)

5 – 4

(0.20 – 0.16)

Camber 0

Caster 7 40

Wheel rim size

Tire size

Front

Rear

Front

10 5.5 AT

9 8.0 AT

AT22 7-10



AT20 10-9



Rear

4.0

(0.16)

Tire tread depth

Wheel axle runout

TIRE PRESSURE

Front

PartShark.com

kPa kgf/cm

2

4.0

(0.16)

3.0

(0.12) psi

COLD INFLATION

TIRE PRESSURE

FRONT 30 0.30

4.4

REAR 25 0.25

3.6

VEHICLE LOAD CAPACITY LIMIT: 110 kg (243 lbs)

LT-Z250K5 ( 05-MODEL) 10-9

FUEL + OIL

Fuel type

ITEM

Fuel tank capacity including reserve

Reserve

Engine oil type

Engine oil capacity

Final gear oil type

Final gear oil capacity

SPECIFICATION

Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) 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.

10.6 L

(2.8/2.3 US/lmp gal)

Change

2.6 L

(0.7/0.6 US/lmp gal)

SAE 10W-40, API SF or SG

Filter change

2 200 ml

(2.3/1.9 US/lmp qt)

2 300 ml

(2.4/2.0 US/lmp qt)

Overhaul

2 500 ml

(2.6/2.2 US/lmp qt)

Hypoid gear oil SAE #90, API grade GL-5

190 ml

(6.4/6.7 US/lmp oz)

NOTE

E-28, 33

The others

10-10 LT-Z250K5 ( 05-MODEL)

TIGHTENING TORQUE

CHASSIS

Handlebar clamp bolt

Steering shaft holder bolt

ITEM

Steering shaft nut

Wishbone arm pivot bolt/nut (upper and lower)

Wheel hub nut (front)

Wheel hub nut (rear)

Wheel set nut (front and rear)

Steering knuckle nut (upper and lower)

N•m

23

23

49

65

65

138

* 60

29

Front shock absorber mounting bolt/nut (upper and lower)

Tie rod end nut

Tie rod lock nut

Front brake air bleeder valve

Front brake caliper mounting bolt

Front brake pipe nut (Upper and lower)

Front brake pad mounting pin

Front brake caliper holder pin

Front brake caliper holder slide pin

Front brake master cylinder mounting bolt

Front brake hose union bolt

Front brake disc bolt

Front brake disc plate mounting bolt

Footrest bolt (M8)

60

29

29

6.0

26

16

18

18

23

10

23

23

23

26

6.0

2.9

2.9

0.6

2.3

2.6

Footrest bolt (M10)

Rear shock absorber mounting bolt/nut (Upper)

Rear shock absorber mounting bolt/nut (Lower)

Swingarm pivot bolt/nut

Rear brake cam lever bolt/nut

55

78

60

5.5

7.8

6.0

Rear brake pedal mounting bolt 11 1.0

Rear brake panel mounting nut 60 6.0

2.6

1.6

1.8

1.8

2.3

1.0

2.3

2.3

kgf-m

2.3

2.3

4.9

6.5

6.5

13.8

* 6.0

2.9

FRONT BRAKE CALIPER MOUNTING BOLT

Apply THREAD LOCK SUPER 1360 to the caliper mounting bolts before tightening them.



99000-32130: THREAD LOCK SUPER 1360 lb-ft

16.5

16.5

35.5

47.0

47.0

99.9

* 43.5

21.0

43.5

16.5

7.0

16.5

16.5

16.5

19.0

40.0

55.0

43.5

61.5

8.0

8.0

43.5

21.0

21.0

4.4

19.0

11.6

13.0

13.0

FRONT BRAKE HOSE ROUTING

LT-Z250K5 ( 05-MODEL) 10-11

 

LT-Z250K6 ( 06-MODEL)

LT-Z250K6 ( 06-MODEL) 11-1

This chapter describes specifications, service data and servicing procedures which differ from those of the LT-Z250K5 ( 05-MODEL).

NOTE:

* Any differences between the LT-Z250K5 ( 05-MODEL) and LT-Z250K6 ( 06-MODEL) in specifications and service data are indicated with an asterisk mark (*).

* Please refer to the chapter 1 through 10 for details which are not given in this chapter.

CONTENTS

SPECIFICATIONS ......................................................................................... 11- 2

SERVICE DATA ............................................................................................ 11- 3

11

11-2 LT-Z250K6 ( 06-MODEL)

SPECIFICATIONS

DIMENSIONS AND DRY MASS

Overall length ......................................................................................

1 720 mm (67.7 in)

Overall width .......................................................................................

1 070 mm (42.1 in)

Overall height ......................................................................................

1 090 mm (42.9 in)

Wheelbase ..........................................................................................

1 135 mm (44.7 in)

Front track ...........................................................................................

830 mm (32.7 in)

Rear track............................................................................................

810 mm (31.9 in)

Ground clearance................................................................................

230 mm (9.1 in)

Seat height ..........................................................................................

810 mm (31.9 in)

Dry mass.............................................................................................

166 kg (365 lbs)

ENGINE

Type.....................................................................................................

Four-stroke, air-cooled, OHC

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

1

Bore ....................................................................................................

66.0 mm (2.598 in)

Stroke..................................................................................................

72.0 mm (2.835 in)

Displacement ......................................................................................

246 cm 3 (15.0 cu. in)

Compression ratio ...............................................................................

9.2 : 1

Carburetor ...........................................................................................

MIKUNI BSR29, single

Air cleaner ...........................................................................................

Polyurethane foam element

Starter system.....................................................................................

Electric

Lubrication system ..............................................................................

Wet sump

Idle speed ...........................................................................................

1 500 – 100 r/min

DRIVE TRAIN

Clutch ..................................................................................................

Wet multi-plate, automatic, centrifugal type

Transmission .......................................................................................

5-forward and 1-reverse

Gearshift pattern, forward .................................................................

All up, foot lever operated reverse .................................................................

Foot/hand operated

Primary reduction ratio........................................................................

3.047 (64/21)

Secondary reduction ratio ...................................................................

1.133 (17/15)

Gear ratios, Low ..............................................................................

3.083 (37/12)

2nd ...............................................................................

1.933 (29/15)

3rd................................................................................

1.388 (25/18)

4th ................................................................................

1.095 (23/21)

Top ...............................................................................

0.913 (21/23)

Reverse........................................................................

2.833 (34/12)

Final reduction ratio.............................................................................

3.200 (32/10)

CHASSIS

Front suspension.................................................................................

Independent, double wishbone, coil spring, oil damped

Rear suspension .................................................................................

Swingarm type, coil spring, oil damped

Front wheel travel ................................................................................

160 mm (6.3 in)

Rear wheel travel ................................................................................

170 mm (6.7 in)

Caster .................................................................................................

7 40 ............................1G

Trail......................................................................................................

33 mm (1.30 in)............1G

Toe-in ..................................................................................................

5 mm (0.20 in)..............1G

PartShark.com

Rear tire size .......................................................................................

AT20 10- 9

✩

, tubeless

ELECTRICAL

877-999-5686

Ignition type.........................................................................................

Electronic ignition (CDI)

Ignition timing ......................................................................................

5 B .T.D.C. at 1 500 rpm

Spark plug...........................................................................................

NGK DR7EA or DENSO X22ESR-U

Battery.................................................................................................

12 V 28.8 kC (8 Ah)/10 HR

Generator ............................................................................................

Three-phase A.C. generator

Main fuse ............................................................................................

20/15 A

Headlight .............................................................................................

12 V 40/40 W

Brake light/Taillight ..............................................................................

12 V 21/5 W

Neutral indicator light ..........................................................................

12 V 3 W

Reverse indicator light.........................................................................

12 V 3 W

CAPACITIES

Fuel tank, including reserve..............................................................

10.6 L (2.8/2.3 US/Imp gal) reserve .............................................................................

2.6 L (0.7/0.6 US/Imp gal)

Engine oil, oil change.........................................................................

2 200 ml (2.3/1.9 US/Imp qt) filter change .....................................................................

2 300 ml (2.4/2.0 US/Imp qt) overhaul ...........................................................................

2 500 ml (2.6/2.2 US/Imp qt)

Final gear oil change...........................................................................

190 ml (6.4/6.7 US/Imp oz)

SERVICE DATA

VALVE + GUIDE

ITEM

Valve diam.

Tappet clearance (when cold)

Valve guide to valve stem clearance

IN.

EX.

IN.

EX.

IN.

EX.

STANDARD

32

(1.3)

28

(1.1)

0.03 0.08

(0.001 0.003)

0.08 0.13

(0.003 0.005)

0.010 0.037

(0.0004 0.0015)

0.030 0.057

(0.0012 0.0024)

Valve stem deflection

IN. & EX.

Valve guide I.D.

Valve stem O.D.

IN. & EX.

IN.

EX.

5.500 5.512

(0.2165 0.2170)

5.475 5.490

(0.2156 0.2161)

5.455 5.470

(0.2148 0.2154)

Valve stem runout

IN. & EX.

Valve head thickness

IN. & EX.

Valve stem end length

IN. & EX.

Valve seat width

IN. & EX.

0.88 1.08

(0.035 0.043)

Valve head radial runout

Valve spring free length

Valve spring tension

IN. & EX.

PartShark.com

LT-Z250K6 ( 06-MODEL) 11-3

Unit: mm (in)

LIMIT

0.35

(0.014)

0.05

(0.002)

0.5

(0.02)

2.5

(0.10)

0.03

(0.001)

43.0

(1.69)

11-4 LT-Z250K6 ( 06-MODEL)

CAMSHAFT + CYLINDER HEAD

ITEM

Cam height

IN.

Camshaft journal oil clearance

Camshaft journal holder I.D.

EX.

STANDARD

33.780 33.820

(1.3299 1.3315)

32.990 33.030

(1.2988 1.3004)

0.036 0.066

(0.0014 0.0026)

22.012 22.025

(0.8666 0.8671)

21.959 21.976

(0.8645 0.8652)

Unit: mm (in)

LIMIT

33.480

(1.3181)

32.690

(1.2870)

0.150

(0.0059)

Camshaft journal O.D.

Camshaft runout 0.10

(0.004)

Rocker arm I.D.

Rocker arm shaft O.D.

IN. & EX.

IN. & EX.

12.000 12.018

(0.4724 0.4731)

11.977 11.995

(0.4715 0.4722)

Cylinder head distortion

Cylinder head cover distortion

0.05

(0.002)

0.05

(0.002)

CYLINDER + PISTON + PISTON RING

Unit: mm (in)

ITEM

Compression pressure

Piston to cylinder clearance

Cylinder bore

1st

2nd

STANDARD

Piston diam.

Cylinder distortion

Piston ring free end gap

65.955 65.970

(2.5966 2.5972)

PartShark.com

Approx. 8.7 (0.34)

0.10 0.25

65.880

(2.5937)

0.05

(0.002)

7.0

(0.28)

7.2

(0.28)

0.50

(0.020)

Piston ring end gap

1st

(0.004 0.010)

0.50

(0.020)

2nd

0.10 0.25

(0.004 0.010)

Piston ring to groove clearance

1st

0.180

(0.007)

0.150

(0.006)

2nd

Piston ring groove width

0.040 0.050

(0.0016 0.0020)

66.000 66.015

(2.5984 2.5990)

1.01 1.03

(0.0398 0.0406)

1.21 1.23

(0.0476 0.0484)

2.01 2.03

(0.0791 0.0799)

LIMIT

1 200 kPa

(12.0 kgf/cm

2

,

171 psi)

0.120

(0.0047)

66.090

(2.6020)

Oil

1 400 kPa

(14.0 kgf/cm 2 , 199 psi)

LT-Z250K6 ( 06-MODEL) 11-5

ITEM

Piston ring thickness

Piston pin bore

Piston pin O.D.

CONROD + CRANKSHAFT

ITEM

Conrod small end I.D.

Conrod deflection

Conrod big end side clearance

Conrod big end width

Crank web to web width

Crankshaft runout

1st

2nd

STANDARD

0.97 0.99

(0.038 0.039)

1.17 1.19

(0.046 0.047)

16.002 16.008

(0.6300 0.6302)

15.992 16.000

(0.6296 0.6299)

STANDARD

16.006 16.014

(0.6302 0.6305)

0.10 0.45

(0.004 0.018)

17.95 18.00

(0.707 0.709)

53.0 – 0.1

(2.087 – 0.004)

LIMIT

16.030

(0.6311)

15.980

(0.6291)

Unit: mm (in)

LIMIT

16.040

(0.6315)

3.0

(0.12)

1.0

(0.04)

0.08

(0.003)

OIL PUMP

ITEM

Oil pressure (at 60 C, 140 F)

STANDARD

Above 30 kPa (0.3 kgf/cm 2

Below 70 kPa (0.7 kgf/cm 2 at 3 000 r/min

, 4.3 psi)

, 9.9 psi)

CLUTCH

ITEM

Clutch release screw

Drive plate thickness

STANDARD

PartShark.com

Drive plate claw width 11.9 12.0

(0.469 0.472)

Driven plate distortion

Clutch spring free length

Clutch wheel I.D.

Clutch shoe

Clutch engagement r/min

Clutch lock-up r/min

28.9

(1.14)

116.00 116.15

(4.567 4.573)

1 700 2 100 r/min

3 100 3 700 r/min

LIMIT

Unit: mm (in)

LIMIT

2.4

(0.094)

11.0

(0.433)

0.10

(0.004)

27.5

(1.08)

116.5

(4.59)

No groove at any part

11-6 LT-Z250K6 ( 06-MODEL)

DRIVE TRAIN

ITEM

Primary reduction ratio

Secondary reduction ratio

Final reduction ratio

Gear ratios 1st

2nd

3rd

4th

5th

Reverse

Shift fork to groove clearance

Shift fork groove width

Shift fork thickness

Gearshift lever height

Secondary bevel gear backlash

Rear drive (final) bevel gear backlash

Unit: mm (in) Except ratio

LIMIT STANDARD

3.047 (64/21)

1.133 (17/15)

3.200 (32/10)

3.083 (37/12)

1.933 (29/15)

1.388 (25/18)

1.095 (23/21)

0.913 (21/23)

2.833 (34/12)

0.10 0.30

(0.004 0.012)

4.50 4.60

(0.169 0.173)

4.30 4.40

(0.169 0.173)

0 10

(0 0.393)

0.03 0.15

(0.001 0.006)

0.05 0.30

(0.002 0.012)

CARBRETOR

Carburetor type

Bore size

I.D. No.

Idle r/min

Float height

Main jet

Jet needle

Needle jet

SPECIFICATION

ITEM

E-19, 28

MIKUNI BSR29

E-33

←

←

29 mm

(1.14 in)

(M.J.)

(J.N.)

21G0

1 500 – 100 r/min

13.0 – 1.0 mm

(0.51 – 0.04 in)

#125

5DH54-2nd

21G1

PartShark.com

#

←

←

←

(N.J.)

(P.J.)

877-999-5686

P-0M

#20

#

# Pilot jet

Pilot screw

(P.S.) 1 and 1/2 turns back PRE-SET

Throttle cable play 3 5 mm

(0.12 0.20 in)

0.5 1.0 mm

(0.02 0.04 in)

←

Starter (enricher) plunger cable play

←

0.5

(0.020)

LT-Z250K6 ( 06-MODEL) 11-7

ELECTRICAL

Spark plug

ITEM

Spark performance

Ignition coil resistance

Ignition coil primary peak voltage

Generator coil resistance

Pick-up coil peak voltage

Generator no-load voltage

(When engine is cold)

Generator Max. output

Regulated voltage

Starter relay resistance

Battery Type designation

Capacity

Fuse size

Type

Gap

Primary

SPECIFICATION

NGK: DR7EA

DENSO: X22ESR-U

0.6 0.7

(0.024 0.028)

Over 8 (0.3) at 1 atm.

0.05 1.0

Ω

Secondary

Pick-up

Charging

10.5 19.0 k

Ω

120 V and more

80 155

Ω

0.5 1.2

Ω

4.0 V and more

65 V (AC) and more at 5 000 r/min

Approx. 150 W at 5 000 r/min

14.0 15.5 V at 5 000 r/min

3 6

Ω

YTX9-BS

12V 28.8 kC (8 Ah)/10HR

20 A

WATTAGE

Headlight

ITEM

HI

LO

SPECIFICATION

40

40

21/5 Brake light/Taillight

Reverse indicator light

Neutral indicator light

3

877-999-5686

Unit: mm (in)

NOTE

Terminal

Terminal

Plug cap

Terminal

+

: B/W

-

: W/Bl

Bl/Y G/W

Y Y

+

: G/W

-

: Bl/Y

Unit: W

11-8 LT-Z250K6 ( 06-MODEL)

BRAKE + WHEEL

ITEM

Rear brake lever play

Unit: mm (in)

LIMIT

Rear brake pedal free travel

STANDARD/SPECIFICATION

3 5

(0.12 0.20)

20 30

(0.79 1.18)

2.8 3.2

(0.110 0.126)

Brake disc thickness

Brake disc runout

Brake drum I.D.

Front

Front

Rear

2.5

(0.098)

0.30

(0.012)

140.7

(5.54)

Master cylinder bore

Master cylinder piston diam.

Brake caliper cylinder bore

Front

Front

Front

12.700 12.743

(0.5000 0.5017)

12.657 12.684

(0.4983 0.4994)

32.030 32.080

(1.2610 1.2630)

Brake caliper piston diam.

Brake fluid type

Turning radius

Toe-in (with 75 kg, 165 lbs)

Front

31.948 31.998

(1.2578 1.2598)

DOT 4

2.7 m (8.9 ft)

5 – 4

(0.20 – 0.16)

Camber 0

Caster 7 40

Wheel rim size Front 10 5.5 AT

Tire size

Rear

Front

Rear

9 8.0 AT

AT22 7-10

✩✩

AT20 10-9

✩

Tire tread depth

Wheel axle runout

TIRE PRESSURE

4.0

(0.16)

Front

PartShark.com

kPa kgf/cm 2

4.0

(0.16)

3.0

(0.12) psi

COLD INFLATION

TIRE PRESSURE

FRONT

REAR

30

25

0.30

0.25

4.4

3.6

VEHICLE LOAD CAPACITY LIMIT: 110 kg (243 lbs)

LT-Z250K6 ( 06-MODEL) 11-9

FUEL + OIL

Fuel type

ITEM

Fuel tank capacity including reserve

Reserve

Engine oil type

Engine oil capacity

Final gear oil type

Final gear oil capacity

SPECIFICATION

Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) 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.

10.6 L

(2.8/2.3 US/lmp gal)

2.6 L

(0.7/0.6 US/lmp gal)

* SAE 10W-40, API SF/SG or SH/SJ with JASO MA

Change

Filter change

2 200 ml

(2.3/1.9 US/lmp qt)

2 300 ml

(2.4/2.0 US/lmp qt)

Overhaul

2 500 ml

(2.6/2.2 US/lmp qt)

Hypoid gear oil SAE #90, API grade GL-5

190 ml

(6.4/6.7 US/lmp oz)

NOTE

E-28, 33

The others

LT-Z250K7 ( 07-MODEL)

LT-Z250K7 ( 07-MODEL) 12-1

NOTE:

* The specification and service data are the same as the K6-MODEL

CONTENTS

I NFORMATION LABEL INSTALLATION (For E-33) ................................... 12- 2

12

12- 2 LT-Z250K7 ( 07-MODEL)

INFORMATION LABEL INSTALLATION (For E-33)

Frame LH side

10 ± 5 mm

LABEL

– 2 –

LT-Z250K8 ( 08-MODEL)

LT-Z250K8 ( 08-MODEL) 13-1

NOTE:

* The specification and service data are the same as the K7-MODEL

CONTENTS

I NFORMATION LABEL ............................................................................... 13- 2

13

13-2 LT-Z250K8 ( 08-MODEL)

INFORMATION LABELS

No.

LABEL or PLATE NAME

1

Certification plate

E

2

Information label

E

3

Gearshift pattern label

E

4

Gearshift pattern label

E

/

F

5

Tire air pressure label

E

6

Tire air pressure label and warning no-passenger label

F

7

General warning label

E

8

General warning label

F

9

Warning no-passenger label

E

0

Age, 16 Iabel

E

A

Age, 16 Iabel

F

B

Manual notice label

E

C

Gearshift label

E

D

Gearshift label

F

E

ICES Canada label

E

/

F

F

Compliance label

E

G

EC approval mark

H

Compliance label

* E-28: Fuel caution label enclosed.

E

: English

F

: French

A: Attached

E-19

APPLIED SPECIFICATION

E-28 E-33

A A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A A

A

A

A

A

A

A

A

– 2 –

Front of left side frame

LT-Z250K9 (’09 MODEL)

1

LT-Z250K9 (’09 MODEL) 14-1

6JKUEJCRVGTFGUETKDGUUGTXKEGURGEKHKECVKQPUUGTXKEGFCVCCPFUGTXKEKPIRTQEGFWTGTUYJKEJ

FKHHGTHTQOVJQUGQHVJG.6<-ŏ/1&'.

016'

#P[FKHHGTGPEGUDGVYGGPVJG.6<-ŏ/1&'.CPF.6<-ŏ/1&'.

KPURGEKHKECVKQPUCTGENGCT[KPFKECVGFYKVJCPCUVGTKUMOCTM

2NGCUGTGHGTVQVJGECRVGTUVJTQWIJHQTFGVCKNUYJKEJCTGPQVIKXGPKPVJKUEJCRVGT

CONTENTS

PAGE

52'%+(+%#6+105

5'48+%'&#6#

(7'.6#0-%105647%6+10

%#4$74'614

+0(14/#6+10.#$'.5

14

14- 2 LT-Z250K9 ( 09-MODEL)

SPECIFICATIONS

DIMENSIONS AND CURB MASS

Overall length ......................................................................................

1 720 mm (67.7 in)

Overall width........................................................................................

1 070 mm (42.1 in)

Overall height ......................................................................................

1 090 mm (42.9 in)

Wheelbase ..........................................................................................

1 135 mm (44.7 in)

Front track ...........................................................................................

830 mm (32.7 in)

Rear track............................................................................................

810 mm (31.9 in)

Ground clearance................................................................................

230 mm (9.1 in)

Seat height ..........................................................................................

810 mm (31.9 in)

* Curb mass ........................................................................................

177 kg (390 lbs)

ENGINE

Type.....................................................................................................

4-stroke, air-cooled, OHC

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

1

Bore.....................................................................................................

66.0 mm (2.598 in)

Stroke ..................................................................................................

72.0 mm (2.835 in)

Displacement ......................................................................................

246 cm

3

(15.0 cu. in)

Compression ratio ...............................................................................

9.2 : 1

Carburetor ...........................................................................................

MIKUNI BSR29, single

Air cleaner ...........................................................................................

Polyurethane foam element

Starter system .....................................................................................

Electric

Lubrication system ..............................................................................

Wet sump

Idle speed............................................................................................

1 500 ± 100 r/min

DRIVE TRAIN

Clutch ..................................................................................................

Wet multi-plate, automatic, centrifugal type

Transmission .......................................................................................

5-speed forward with reverse

Gearshift pattern, forward..................................................................

All up, foot operated reverse ..................................................................

Foot/hand operated

Primary reduction ratio ........................................................................

3.047 (64/21)

Gear ratios, Low ................................................................................

3.083 (37/12)

2nd ................................................................................

1.933 (29/15)

3rd .................................................................................

1.388 (25/18)

4th .................................................................................

1.095 (23/21)

Top.................................................................................

0.913 (21/23)

Reverse .........................................................................

2.833 (34/12)

Secondary reduction ratio ...................................................................

1.133 (17/15)

Final reduction ratio.............................................................................

3.200 (32/10)

CHASSIS

Front suspension .................................................................................

Independent, double wishbone, coil spring, oil damped

Rear suspension .................................................................................

Swingarm type, coil spring, oil damped

Front wheel travel ................................................................................

160 mm (6.3 in)

Rear wheel travel ................................................................................

170 mm (6.7 in)

Caster..................................................................................................

7° 40’

Trail......................................................................................................

33 mm (1.30 in)

Toe-in...................................................................................................

5 mm (0.20 in)

PartShark.com

Front tire ..............................................................................................

AT22 7-10 , tubeless

Rear tire ..............................................................................................

AT20

×

10- 9

°

, tubeless

ELECTRICAL

877-999-5686

Ignition type .........................................................................................

Electronic ignition (CDI)

Ignition timing ......................................................................................

5° B.T.D.C. at 1 500 r/min

Spark plug ...........................................................................................

NGK DR7EA or DENSO X22ESR-U

Battery.................................................................................................

12 V 28.8 kC (8 Ah)/10 HR

Generator ............................................................................................

Three-phase A.C. generator

Main fuse.............................................................................................

20 A

Fuse ....................................................................................................

15 A

Headlight .............................................................................................

12 V 40/40 W

Brake/Tail light .....................................................................................

12 V 21/5 W

Neutral indicator light...........................................................................

12 V 3 W

Reverse indicator light .........................................................................

12 V 3 W

CAPACITIES

Fuel tank, including reserve ..............................................................* 9.7 L (2.6/2.1 US/Imp gal) reserve .............................................................................* 2.1 L (0.6/0.5 US/Imp gal)

Engine oil, oil change.........................................................................

2 200 ml (2.3/1.9 US/Imp qt) with filter change ..............................................................

2 300 ml (2.4/2.0 US/Imp qt) overhaul............................................................................

2 500 ml (2.6/2.2 US/Imp qt)

Final gear oil........................................................................................

190 ml (6.4/6.7 US/Imp oz)

LT-Z250K9 ( 09 MODEL) 14-3

SERVICE DATA

CARBRETOR

Carburetor type

Bore size

ITEM

I.D. No.

Idle r/min

Float height

Main jet

Jet needle

Needle jet

Pilot jet

Pilot screw

Throttle cable play

Starter (enricher) plunger cable play

(M.J.)

(J.N.)

(N.J.)

(P.J.)

(P.S.)

* E-19

MIKUNI BSR29

29 mm

(1.14 in)

21G0

1 500 ± 100 r/min

13.0 ± 1.0 mm

(0.51 ± 0.04 in)

#125

5DH54-2nd

P-0M

#20

SPECIFICATION

1 and 1/2 turns back

3 – 5 mm

(0.12 – 0.20 in)

0.5 – 1.0 mm

(0.02 – 0.04 in)

* E-28, 33

←

←

21G1

←

←

#

←

#

#

PRE-SET

←

←

FUEL + OIL

ITEM SPECIFICATION

Fuel type Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the Research Method.

Gasoline containing MTBE (MethyI Tertiary

ButyI Ether), less than 10% ethanol, or less than

Fuel tank capacity including reserve

Reserve

5% methanol with appropriate cosolvents and

PartShark.com

* 9.7 L

(2.6/2.1 US/lmp gal)

(0.6/0.5 US/lmp gal)

SAE 10W-40, API SF/SG or SH/SJ with JASO MA Engine oil type

Engine oil capacity

Final gear oil type

Final gear oil capacity

Change

Filter change

2 200 ml

(2.3/1.9 US/lmp qt)

2 300 ml

(2.4/2.0 US/lmp qt)

Overhaul

2 500 ml

(2.6/2.2 US/lmp qt)

Hypoid gear oil SAE #90, API grade GL-5

190 ml

(6.4/6.7 US/lmp oz)

NOTE

E-28, 33

E-19

14- 4 LT-Z250K9 ( 09-MODEL)

FUEL TANK CONSTRUCTION

1

Fuel tank

2

Fuel cap

3

Breather hose

4

Gasket

5

Gasket

6

Fuel valve

7

Fuel hose

LT-Z250K9 ( 09 MODEL) 14-5

CARBURETOR

PILOT SCREW REMOVAL (For E-28, 33)

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 4 mm (0.16 in) 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.

1

Drill-stop

2

Plug

3

Pilot screw

4

Carburetor body

PILOT SCREW REASSEMBLY (For E-28, 33)

• After cleaning, install the pilot screw

1

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

Pilot screw

2

877-999-5686

14- 6 LT-Z250K9 ( 09-MODEL)

INFORMATION LABELS

Information label (E-28)

Certification label (E-33)

Front of frame right side

FWD