Suzuki DR-Z70 Service Manual

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Printed in USA

K8

99500-40030-03E DR-Z70K8_03E SERVICE MANUAL 2007. 5. 15 for PS printing

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9 9 5 0 0 - 4 0 0 3 0 - 0 3 E

FOREWORD

This manual contains an introductory description on the SUZUKI DR-Z70 and procedures for its inspection/service and overhaul of its main components.

Other information considered as generally known is not included.

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

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

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

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

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

#

Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual.

Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider.

GROUP INDEX

GENERAL INFORMATION

PERIODIC MAINTENANCE

ENGINE

FUEL SYSTEM

CHASSIS

ELECTRICAL SYSTEM

SERVICING INFORMATION

4

5

6

1

2

3

7

© COPYRIGHT SUZUKI MOTOR CORPORATION 2007

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, is its exploded view. Work instructions and other service information such as the tightening torque, lubricating points and locking agent points, are provided.

Example: Front wheel and front brake

1 Front axle

2 Spacer (R)

3 Dust seal

4 Bearing (R)

5 Spacer

6 Front wheel rim

7 Bearing (L)

8 Spring

9 Brake shoe

0 Brake camshaft

A Brake panel

B Brake cam lever

A Front axle nut

B Brake cam lever nut

"

ITEM N·m kgf-m lb-ft

A 53 5.3

38.5

B 3 0.3

2.0

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.

Measure in voltage range.

Apply oil. Use engine oil unless otherwise specified.

Apply molybdenum oil solution.

(mixture of engine oil and SUZUKl

MOLY PASTE in a ratio of 1 : 1)

Apply SUZUKI SUPER GREASE “ A ” or equivalent grease.

99000-25010

Apply SUZUKI BOND “ 1215 ” or equivalent bond.

99000-31110

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

99000-32110

Measure in resistance range.

Measure in diode test range.

Measure in continuity test range.

Use special tool.

Indicates service data.

1-1 GENERAL INFORMATION

GENERAL INFORMATION

CONTENTS

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

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

SUZUKI DR-Z70K8 (’08-MODEL) .................................................................1- 4

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

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

FUEL (FOR USA AND CANADA)...........................................................1- 5

FUEL (FOR OTHER COUNTRIES) .........................................................1- 5

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

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

BREAK-IN 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

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

EFFECTIVE FRAME NO.

CODE

E-28

E-33

COUNTRY or AREA

Canada

U.S.A.

JS1JB41A 82100001-

GENERAL INFORMATION 1-2

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.

1

Indicates a potential hazard that could result in motorcycle damage.

NOTE:

Indicates special information to make maintenance easier or instructions clearer.

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

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

GENERAL PRECAUTIONS

#

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

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

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

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

* Never use gasoline as a cleaning solvent.

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

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

6

1-3 GENERAL INFORMATION

* 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 performing service to electrical parts, if the service procedures do not require use of battery power, disconnect the coupler from the battery.

* When tightening the cylinder head or 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: batteries and tires.

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

SUZUKI DR-Z70K8 (’08-MODEL)

GENERAL INFORMATION 1-4

RIGHT SIDE

LEFT SIDE

• Difference between illustration and actual motorcycle may exist depending on the markets.

SERIAL NUMBER LOCATION

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

1-5 GENERAL INFORMATION

FUEL AND OIL RECOMMENDATION

FUEL (FOR USA AND CANADA)

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 (Methyl Tertiary Butyl Ether), less than 10 % ethanol, or less than 5 % methanol with appropriate cosolvents and corrosion inhibitor is permissible.

FUEL (FOR OTHER COUNTRIES)

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

ENGINE OIL (FOR USA)

Oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil.

Suzuki recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or equivalent engine oil. Use of

SF/SG or SH/SJ in API with MA in JASO.

Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an alternative according to the following chart.

ENGINE OIL (FOR OTHER COUNTRIES)

Oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil. Use of SF/SG or

SH/SJ in API with MA in JASO.

Suzuki recommends the use of SAE 10W-40 engine oil. If SAE

10W-40 engine oil is not available, select an alternative according to the right chart.

20W-50

15W-40. 15W-50

10W-40. 10W-50

10W-30

BREAK-IN PROCEDURES

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

• Keep to these break-in throttle position:

Initial 10 hours: Less than 1/2 throttle

Up to 20 hours: Less than 3/4 throttle

INFORMATION LABELS

No LABEL or PLATE NAME

4

5

6

7

1

2

3

8

9

0

A

Noise label

Information label

Fuel caution label

Manual notice Label

General warning label E

General warning label F

Manufacturer label

Compliance label E

ICES Canada label

EC mark label

Compliance label E / F

E : English F : French

Forward Forward

GENERAL INFORMATION 1-6

APPLIED SPECIFICATION

– c c c c

– c c

E28

–

– c

E33 c c

– c c

– c

–

–

–

–

Left

Front fork

Right

E33

Rear fender

E28

1-7 GENERAL INFORMATION

SPECIFICATIONS

DIMENSIONS AND DRY MASS

Overall length..........................................................................

1 320 mm (52.0 in)

Overall width ...........................................................................

580 mm (22.8 in)

Overall height..........................................................................

790 mm (31.1 in)

Wheelbase ..............................................................................

935 mm (36.8 in)

Ground clearance ...................................................................

135 mm (5.3 in)

Seat height..............................................................................

560 mm (22.0 in)

Dry mass.................................................................................

53 kg (116 lbs)

ENGINE

Type ........................................................................................

4 stroke, air-cooled, OHC

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

1

Bore ........................................................................................

48.0 mm (1.890 in)

Stroke......................................................................................

37.0 mm (1.457 in)

Displacement ..........................................................................

67 cm³ (4.1 cu.in)

Compression ratio...................................................................

9.5:1

Carburetor...............................................................................

MIKUNI VM13SH

Air cleaner...............................................................................

Polyurethane foam element

Starter system.........................................................................

Electric and kick

Lubrication system ..................................................................

Wet sump

Idle speed ...............................................................................

1 600 ± 100 r/min

DRIVE TRAIN

Clutch......................................................................................

Wet shoe, auto matic, centrifugal type

Transmission...........................................................................

3-speed constant mesh

Gearshift pattern .....................................................................

3-up

Primary reduction ratio............................................................

3.823 (65/17)

Final reduction ratio ................................................................

2.538 (33/13)

Gear rations, Low ...................................................................

3.400 (34/10)

2nd ....................................................................

1.812 (29/16)

Top ....................................................................

1.200 (24/20)

Drive chain ..............................................................................

D.I.D 428, 78 links

GENERAL INFORMATION 1-8

CHASSIS

Front suspension..................................................................... Inverted telescopic, coil spring

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

Front fork stroke ...................................................................... 96 mm (3.8 in)

Rear wheel travel .................................................................... 76 mm (3.0 in)

Caster...................................................................................... 25 ° 20 ’

Trail ......................................................................................... 35 mm (1.38 in)

Steering angle ......................................................................... 45 ° (right & left)

Turning radius ......................................................................... 1.4 m (4.6 ft)

Front brake .............................................................................. Drum brake

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

Front tire size .......................................................................... 2.50-10 33J, tube type

Rear tire size ........................................................................... 2.50-10 33J, tube type

ELECTRICAL

Ignition type ............................................................................. Electronic ignition (CDI)

Ignition timing .......................................................................... 15 ° B.T.D.C at 1 600 r/min

Spark plug ............................................................................... NGK CR7HSA or DENSO U22FSR-U

Battery ..................................................................................... 12 V 8.28 kC (2.3 Ah)/10 HR

Generator ................................................................................ Single-phase A.C. generator

Main fuse................................................................................. 10 A

CAPACITIES

Fuel tank, including reserve ....................................................

3.0 L (0.8/0.7 US/lmp gal)

Reserve..................................................................

0.8 L (0.2/0.2 US/lmp gal)

Engine oil, oil change ..............................................................

700 ml (0.7/0.6 US/Imp qt) overhaul ................................................................

800 ml (0.8/0.7 US/lmp qt)

These specifications are subject to change without notice.

2-1 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE

CONTENTS

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

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

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

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

AIR CLEANER .......................................................................................2- 4

EXHAUST PIPE BOLTS AND MUFFLER MOUNTING NUT ................2- 5

VALVE CLEARANCE ............................................................................2- 6

SPARK PLUG ........................................................................................2- 8

SPARK ARRESTER ...............................................................................2- 9

FUEL LINE .............................................................................................2- 9

ENGINE OIL ...........................................................................................2-10

THROTTLE CABLE PLAY .....................................................................2-11

IDLE SPEED ...........................................................................................2-11

CLUTCH .................................................................................................2-11

DRIVE CHAIN .........................................................................................2-12

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

TIRES .....................................................................................................2-14

SPOKE NIPPLES ...................................................................................2-15

STEERING ..............................................................................................2-16

FRONT FORK ........................................................................................2-16

REAR SUSPENSION .............................................................................2-16

CHASSIS BOLTS AND NUTS ...............................................................2-17

COMPRESSION PRESSURE CHECK .........................................................2-18

COMPRESSION TEST PROCEDURE ...................................................2-18

OIL PRESSURE CHECK ..............................................................................2-19

OIL PRESSURE TEST PROCEDURE ...................................................2-19

AUTOMATIC CLUTCH INSPECTION ..........................................................2-20

1. INITIAL ENGAGEMENT INSPECTION ..............................................2-20

2. CLUTCH “LOCK-UP” INSPECTION .................................................2-20

PERIODIC MAINTENANCE 2-2

PERIODIC MAINTENANCE SCHEDULE

The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy.

NOTE:

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

PERIODIC MAINTENANCE CHART

Interval

Item

Air cleaner element

Exhaust pipe bolts and muffler mounting nut

Valve clearance

Spark plug

Spark arrester

Fuel line

Engine oil

Throttle cable

Idle speed

Clutch

Drive chain

Brakes

Tires

Spoke nipples

Steering

Front fork

Rear suspension

Chassis nuts and bolts

Initially

1 month

Every

6 months

Every

12 months

Inspect each time the motorcycle is ridden and clean as necessary.

T

I

—

—

T

I

I

C

T

I

R

C

I

I

I

R

I

I

I

R

I

I

Clean, oil and inspect each time the motorcycle is ridden.

I

I

I

I

R

I

I I

— I I

Inspect each time the motorcycle is ridden.

I

T

I

I

I

I

—

T

I

I

I

T

NOTE:

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

C= Clean

R = Replace

T = Tighten

2

6

2-3 PERIODIC MAINTENANCE

LUBRICATION POINTS

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

Major lubrication points are indicated below.

Side-stand pivot and spring hook

Throttle cable

Drive chain

Front brake lever holder

Brake pedal pivot Kick starter lever

NOTE:

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

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

MAINTENANCE AND TUNE-UP

PROCEDURES

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

AIR CLEANER

Inspect each time the motorcycle is ridden and clean as necessary.

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

• Remove the air cleaner box cover 1 .

• Remove the air cleaner element 2 .

PERIODIC MAINTENANCE 2-4

• Fill a container with a non-flammable cleaning solvent.

• Immerse the air cleaner element in the cleaning solvent and wash it.

• Squeeze the cleaning solvent out of the washed element by pressing it between the palms of both hands: do not twist or wring the element or it will develop tears.

• Immerse the element in air filter oil and squeeze the oil out of the element leaving it slightly wet with oil.

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

A Non-flammable cleaning solvent

B Air filter oil

2-5 PERIODIC MAINTENANCE

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

The open mesh A of the air cleaner element must be faced outside.

The surest way to accelerate engine wear is to operate the engine without the element or to use a torn element. Make sure that the air cleaner is in good condition at all times. The life of the engine depends largely on this component.

• Remove the drain plug 4 to allow any water to drain out.

EXHAUST PIPE BOLTS AND MUFFLER

MOUNTING NUT

Tighten initially at 1 month and every 6 months thereafter.

• Tighten the exhaust pipe bolts 1 and muffler mounting nut 2 to the specified torque.

"

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

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

VALVE CLEARANCE

Inspect initially at 1 month and every 6 months thereafter.

REMOVAL

• Remove the spark plug. ( 2-8)

• Remove the camshaft sprocket cover 1 .

• Remove the valve inspection caps 2 .

• Remove the TDC plug 3 and generator cover plug 4 .

INSPECTION

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

NOTE:

* The piston must be at “TDC” on the compression stroke in order to check the valve clearance or to adjust valve clearance.

* The clearance specification is for COLD state.

* To turn the crankshaft for clearance checking, and rotate in the normal running direction.

Valve clearance (when cold):

IN.: 0.04 – 0.07 mm (0.0016 – 0.0028 in)

EX.: 0.05 – 0.10 mm (0.0020 – 0.0039 in)

PERIODIC MAINTENANCE 2-6

2-7 PERIODIC MAINTENANCE

• Turn the crankshaft to bring the “Top” line A on the generator rotor to the center of hole on the generator cover and also to bring the mark B on the camshaft sprocket with the concave line C of the cylinder head as shown.

• Insert a thickness gauge between the valve stem end and the adjusting screw on the rocker arm.

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

\

09900-20803: Thickness gauge

09917-14910: Valve clearance adjusting driver

"

Valve adjuster lock-nut: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

• After finishing the valve clearance adjustment, reinstall the following items.

* TDC plug ( 3-70)

* Generator cover plug ( 3-70)

* Camshaft sprocket cover ( 3-69)

* Spark plug ( 2-8)

Adjusting screw

Lock-nut

PERIODIC MAINTENANCE 2-8

SPARK PLUG

Inspect every 6 months.

Replace every 12 months.

REMOVAL

• Disconnect the spark plug cap 1 and remove the spark plug

2 .

HEAT RANGE

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

\

09930-10121: Spark plug wrench set

NGK

DENSO

Hot type

CR6HSA

U20FSR-U

Standard

CR7HSA

U22FSR-U

Cold type

CR8HSA

U24FSR-U

CARBON DEPOSIT

Inspect the carbon deposit on the spark plug.

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

SPARK PLUG GAP

Measure the spark plug gap with a thickness gauge. Adjust the spark plug gap if necessary.

Spark plug gap:

Standard: 0.6 – 0.7 mm (0.024 – 0.028 in)

\

09900-20803: Thickness gauge

ELECTRODE’S CONDITION

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

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

0.6 – 0.7 mm

(0.024 – 0.028 in)

2-9 PERIODIC MAINTENANCE

INSTALLATION

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

• Tighten the spark plug to the specified torque.

"

Spark plug: 11 N·m (1.1 kgf-m, 8.0 lb-ft)

\

09930-10121: Spark plug wrench set

SPARK ARRESTER

Clean every 6 months.

#

A hot muffler can burn you. The muffler will be hot enough to burn you for some time after stopping the engine.

Wait until the muffler cools to avoid burns.

• Remove the spark arrester 1 and gasket 2 .

• Remove carbon deposits from the spark arrester by using a brush.

Be careful to avoid damaging the spark arrester screen.

Inspect the spark arrester for damage. If any defects are found, replace the spark arrester with a new one.

• Install the gasket 2 and spark arrester 1 .

The removed gasket must be replaced with a new one to prevent exhaust gas leakage.

• Tighten the spark arrester bolts 3 to the specified torque.

"

Spark arrester bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

FUEL LINE

Inspect initially at 1 month and every 6 months thereafter.

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

ENGINE OIL

ENGINE OIL REPLACEMENT

Replace initially at 1 month and every 6 months thereafter.

• Engine oil should be changed while the engine is warm.

• Place the motorcycle on the side-stand.

• Place an oil pan below the engine. Drain oil by removing the engine oil drain plug 1 .

• Remove the oil filler cap 2 .

• Tighten the engine oil drain plug 1 to the specified torque.

Pour new oil through the oil filler hole. The engine will hold about 700 ml of oil. Use oil of SF/SG or SH/SJ in API with MA in JASO.

"

Engine oil drain plug: 18 N·m (1.8 kgf-m, 13.0 lb-ft)

• Install the oil filler cap 2 .

• Start up the engine and allow it to run about three minutes at idling speed.

• Turn off the engine and wait about three minutes.

• Remove the filler cap 2 and wipe off the oil with a clean rag.

• Holding the motorcycle vertically.

• Insert the filler cap 2 until the threads touch the filler neck, but do not to screw the cap in.

• Draw out the filler cap 2 and check the oil level.

• If the level is below mark “L” add oil to “F” level.

• If the level is above mark “F” drain oil to “F” level.

• Install the filler cap.

NECESSARY AMOUNT OF ENGINE OIL

Oil change : 700 ml (0.7/0.6 US/Imp qt)

Engine overhaul : 800 ml (0.8/0.7 US/Imp qt)

PERIODIC MAINTENANCE 2-10

F

L

2-11 PERIODIC MAINTENANCE

THROTTLE CABLE PLAY

Inspect initially at 1 month and every 6 months thereafter.

Adjust the throttle cable play A as follows.

• Pull the throttle adjuster cover 1 .

• Loosen the lock-nut 2 of the throttle cable.

• Turn the adjuster 3 in or out until the throttle cable play A should be 2.0 – 4.0 mm (0.08 – 0.16 in) at the throttle grip.

• Tighten the lock-nut 2 while holding the adjuster 3 .

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

#

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

IDLE SPEED

Inspect initially at 1 month and every 6 months thereafter.

• Adjust the throttle cable play. ( Above)

NOTE:

Warn up the engine before adjusting the engine idle speed.

• Connect a tachometer.

• Start the engine, turn the throttle stop screw and set the engine idle speed as follows.

Engine idle speed: 1 600 ± 100 r/min

\

09900-26006: Tachometer

CLUTCH

Inspect initially at 1 month and every 6 months thereafter.

• Loosen the lock-nut 1 .

• First, turn the release screw 2 clockwise by one turn and turn it counterclockwise until resistance is felt then turn it clockwise by 1/8 turn.

• Tighten the lock-nut 1 while holding the release screw 2 .

DRIVE CHAIN

Clean, oil and inspect each time the motorcycle is ridden.

Visually inspect the drive chain for the possible defects listed below.

* Loose pins

* Damaged rollers

* Dry or rusted links

* Twisted or seized links

* Excessive wear

* Kinked or binding links

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

NOTE:

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

The standard drive chain is D.I.D 428. SUZUKI recommends to use this standard drive chain as a replacement.

CHECKING

• Loosen the rear axle nut 1 .

• Tense the drive chain fully by turning both chain adjusters 2 after looseing the lock-nuts 3 .

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

Drive chain 20-pitch length: 259.0 mm (10.20 in)

NOTE:

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

PERIODIC MAINTENANCE 2-12

2-13 PERIODIC MAINTENANCE

ADJUSTING

• Place the motorcycle on the side-stand.

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

25 – 35 mm (1.0 – 1.4 in) of slack at the middle of the chain between the engine and rear sprockets as shown. The reference marks 2 must be at the same position on the scale to ensure that the front and rear wheels are correctly aligned.

Drive chain slack: 25 – 35 mm (1.0 – 1.4 in)

• After adjusting the drive chain, tighten the rear axle nut 3 to the specified torque.

"

Rear axle nut: 54 N·m (5.4 kgf-m, 39.0 ib-ft)

• Recheck the drive chain slack after tightening the axle nut and readjust if necessary.

• Tighten both lock-nuts 4 securely.

CLEANING AND LUBRICATING

• Clean the drive chain with kerosine.

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

25 – 35 mm (1.0 – 1.4 in)

The drive chain joint clip should be attached in the way that the slit end will face opposite to the direction of travel.

Direction of travel

PERIODIC MAINTENANCE 2-14

BRAKES

Inspect initially at 1 month and every 6 months thereafter.

FRONT BRAKE LEVER PLAY

• Adjust the brake lever position.

• Adjust the free travel A to 15 – 25 mm (0.6 – 1.0 in) by turning the adjusting nut 1 .

Front brake lever play A : 15 – 25 mm (0.6 – 1.0 in)

REAR BRAKE ADJUSTMENT

• Adjust the free travel B to 15 – 20 mm (0.6 – 0.8 in) by turning the adjusting nut 2 .

Brake pedal free travel B : 15 – 20 mm (0.6 – 0.8 in)

FRONT AND REAR BRAKE SHOE WEAR

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

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

• First, check if the brake system is properly adjusted.

• While operating the brake, check to see that brake lining wear indicator line 1 is within the wear indicator mark 2 on the brake panel.

• If the brake lining wear indicator line 1 is reached the wear indicator mark 2 , the brake shoe assembly must be replaced with a new set of shoe. ( 5-7)

TIRES

Inspect every 6 months.

TIRE TREAD CONDITION

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

\

09900-20805: Tire depth gauge

Tire tread depth (Front and Rear):

Service Limit: FRONT AND REAR: 4.0 mm (0.16 in)

Front Rear

2-15 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

Front: 100 kPa (1.0 kgf/cm², 14 psi)

Rear: 125 kPa (1.25 kgf/cm², 18 psi)

The standard tire fitted on this motorcycle is a 2.50-10

33J for front and rear. The use of tires other than those specified may cause instability. It is highly recommended to use the specified tires.

SPOKE NIPPLES

Inspect each time the motorcycle is redden.

Make sure that the nipples are tight. If necessary, tighten them with a spoke nipple wrench.

"

Spoke nipple: 2 N·m (0.2 kgf-m, 1.5 lb-ft)

\

09940-60113: Spoke nipple wrench

STEERING

Inspect initially at 1 month and every 6 months thereafter.

The steering should be adjusted properly for smooth turning of handlebars and safe operation. Overtight steering prevents smooth turning of the handlebars and too loose steering will cause poor stability. Check that there is no play in the steering stem. Support the motorcycle so that the front wheel is off the ground. With the wheel facing straight ahead, grasp the front fork near the axle and pull forward. If play is found, adjust the steering. ( 5-18)

FRONT FORK

Inspect initially at 1 month and every 6 months thereafter.

• Remove the front fork covers. ( 5-3)

Inspect the front forks for grease, scoring or scratches on the outer surface of the inner tubes. Clean or replace any defective parts, if necessary.

REAR SUSPENSION

Inspect initially at 1 month and every 12 months thereafter.

Replace any defective parts if necessary.

• Remove the seat. ( 5-2)

Inspect the rear shock absorber for oil leakage and mounting rubbers on rear shock absorber and swingarm for wear and damage.

PERIODIC MAINTENANCE 2-16

2-17 PERIODIC MAINTENANCE

CHASSIS BOLTS AND NUTS

Tighten initially at 1 month and every 6 months thereafter.

Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to the locations of the following bolts and nuts on the motorcycle.)

ITEM

1 Front axle nut

2 Handlebars set bolts

3 Front fork upper bracket bolts

4 Footrest mounting bolts

5 Rear shock absorber mounting nuts (Upper and Lower)

6 Swingarm pivot nut

7 Brake cam lever nuts (Front and Rear)

8 Rear axle nut

N·m

50

42

3

54

53

23

45

23 kgf-m

5.0

4.2

0.3

5.4

5.3

2.3

4.5

2.3

lb-ft

38.5

16.5

32.5

16.5

36.0

30.5

2.0

39.0

PERIODIC MAINTENANCE 2-18

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 should include compression readings for each maintenance service.

COMPRESSION PRESSURE SPECIFICATION

Standard

1 300 – 1 700 kPa

(13 – 17 kgf/cm², 185 – 242 psi)

Limit

1 100 kPa

(11 kgf/cm², 156 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

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.

Remove the related parts and test the compression pressure in the following manner:

• Remove the spark plug. ( 2-8)

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

• Keep the throttle grip in the fully opened position.

• Press the starter button and crank the engine for a few seconds. Record the maximum gauge reading as the cylinder compression.

\

09915-64512: Compression gauge

09913-10750: Adaptor

2-19 PERIODIC MAINTENANCE

OIL PRESSURE CHECK

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

OIL PRESSURE SPECIFICATION

15 – 40 kPa (0.15 – 0.40 kgf/cm², 2.1 – 5.7 psi) at 3 000 r/min, Oil temp. at 60 °C (140 °F).

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

LOW OIL PRESSURE

* 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 a tachometer to the high-tension cord.

• Remove the exhaust pipe cover 1 .

• Remove the main oil gallery plug 2 .

• Install the oil pressure gauge and adaptor to the main oil gallery.

• Warm up the engine as follows:

Summer: 10 minutes at 2 000 r/min

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

09915-74533: Adaptor

09915-72410: Adaptor

09900-26006: Tachometer

"

Main oil gallery plug: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

AUTOMATIC CLUTCH INSPECTION

This motorcycle is equipped with an automatic clutch. The engagement of the clutch is governed by engine RPMs and centrifugal mechanism located in the clutch.

To insure proper performance and longer lifetime of the clutch assembly it is essential that the clutch engages smoothly and gradually. The following inspections must be performed:

1. INITIAL ENGAGEMENT INSPECTION

• Warm up the engine to normal operating temperature.

• Connect a tachometer to the high-tension cord.

• Seated on the motorcycle with the motorcycle on level ground, increase the engine RPM slowly and note the RPM at which the motorcycle begins to move forward.

\

09900-26006: Tachometer

Clutch engagement: 1 700 – 2 100 r/min

2. CLUTCH “LOCK-UP” INSPECTION

Perform this inspection to determine if the clutch is engaging fully and not slipping.

• Apply the front and rear brakes as firm as possible.

• Briefly open the throttle fully and note the maximum engine

RPMs sustained during the test cycle.

Do not apply full power for more than 3 seconds or damage to the clutch or engine may occur.

Clutch lock-up: 2 900 – 3 500 r/min

PERIODIC MAINTENANCE 2-20

3-1 ENGINE

ENGINE

CONTENTS

ENGINE COMPONENTS REMOVABLE WITH THE ENGINE

IN PLACE ......................................................................................................3- 2

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

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

ENGINE INSTALLATION .......................................................................3- 6

ENGINE DISASSEMBLY ..............................................................................3- 9

ENGINE COMPONENTS INSPECTION AND SERVICE .............................3-21

CYLINDER HEAD ..................................................................................3-21

CYLINDER ..............................................................................................3-32

PISTON AND PISTON PIN ....................................................................3-32

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

CAM CHAIN GUIDE ...............................................................................3-35

CONROD AND CRANKSHAFT .............................................................3-36

OIL PUMP ...............................................................................................3-38

TRANSMISSION ....................................................................................3-39

GEARSHIFT CAM ..................................................................................3-41

GEARSHIFT FORKS ..............................................................................3-41

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

FIRST CLUTCH ......................................................................................3-45

STARTER CLUTCH ...............................................................................3-45

GENERATOR COVER ...........................................................................3-47

CLUTCH COVER ...................................................................................3-47

CRANKCASE .........................................................................................3-49

ENGINE REASSEMBLY ...............................................................................3-52

CRANKSHAFT .......................................................................................3-52

KICK STARTER .....................................................................................3-54

TRANSMISSION ....................................................................................3-55

OIL BREATHER SEPARATOR .............................................................3-56

CRANKCASE .........................................................................................3-56

STARTER IDLE GEAR ..........................................................................3-57

CAM CHAIN ...........................................................................................3-57

STARTER CLUTCH AND GENERATOR ROTOR ................................3-57

GEARSHIFT ...........................................................................................3-58

OIL PUMP AND DRIVE GEAR ..............................................................3-60

GEARSHIFTING CLUTCH .....................................................................3-61

FIRST CLUTCH AND OIL FILTER CASE .............................................3-62

CLUTCH COVER ...................................................................................3-64

GENERATOR COVER ...........................................................................3-64

NEUTRAL SWITCH ................................................................................3-65

PISTON RING .........................................................................................3-65

PISTON ...................................................................................................3-66

CYLINDER ..............................................................................................3-67

CAMSHAFT SPROCKET .......................................................................3-68

CAM CHAIN TENSION ADJUSTER ......................................................3-68

VALVE CLEARANCE INSPECTION CAP AND CAMSHAFT

SPROCKET COVER ..............................................................................3-69

TDC PLUG AND GENERATOR COVER CAP ......................................3-70

STARTER MOTOR .................................................................................3-70

ENGINE 3-2

ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE

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

ENGINE CENTER

PARTS

Cylinder head

Cylinder

Carburetor

Cam chain tension adjuster

Piston

Camshaft

REMOVAL

3-10

3-12

4-6

3-10

3-12

3-22

INSTALLATION

3-67

3-67

4-11

3-68

3-66

3-30

3

ENGINE LEFT SIDE

Starter idle gear

Engine sprocket

Generator cover

Generator rotor

Neutral switch

PARTS

ENGINE RIGHT SIDE

PARTS

Muffler

Starter motor

Kick starter lever

Spark plug

Gearshiting clutch

First clutch

Oil pump

Oil filter case

Clutch cover

Gearshift shaft

Oil sump filter

Oil pump driver gear

REMOVAL

3-18

3-5

3-13

3-17

3-12

REMOVAL

3-3

3-9

3-9

3-9

3-15

3-14

3-15

3-14

3-13

3-16

3-13

3-15

INSTALLATION

3-57

3-6

3-64

3-57

3-65

INSTALLATION

3-7

3-70

3-70

2-8

3-61

3-62

3-60

3-62

3-64

3-59

3-63

3-60

6

3-3 ENGINE

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.

• Remove the battery. ( 6-6)

• Remove the fuel tank side cover. ( 5-3)

• Drain engine oil. ( 2-10)

• Remove the exhaust pipe bolts 1 .

• Remove the muffler mounting nut 2 and bolt.

• Remove the muffler 3 .

• Remove the exhaust pipe gasket 4 .

• Disconnect the spark plug cap 5 .

• Remove the carburetor 6 .

• Disconnect the starter motor coupler 7 .

• Disconnect the generator coupler 8 and neutral switch coupler 9 .

• Disconnect the ground wire 0 .

• Remove the footrest A .

• Remove the gearshift lever B .

ENGINE 3-4

3-5 ENGINE

• Remove the engine sprocket cover C .

• Remove the engine sprocket E with the drive chain F by removing the snap ring D .

NOTE:

If it is difficult to remove the engine sprocket, loosen the axle nut and chain adjusting nuts to provide additional chain slack.

• Remove the engine from the frame.

ENGINE 3-6

ENGINE INSTALLATION

Install the engine in the reverse order of engine removal.

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

• Tighten the engine mounting nuts to the specified torque.

NOTE:

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

"

Engine mounting nut: 31 N·m (3.1 kgf-m, 22.5 lb-ft)

LH RH

• Install the engine sprocket 1 with the drive chain.

• Install the snap ring 2 .

The removed snap ring must be replaced with a new one.

The drive chain joint clip should be attached in the way that the slit end will face opposite to the direction of travel.

• Install the carburetor.

NOTE:

Install the clamp as shown in the illustration.

Air cleaner box

Upper

RH LH

 

3-7 ENGINE

• Install the exhaust pipe gasket 3 .

The removed gasket must be replaced with a new one to prevent exhaust gas leakage.

• Tighten the exhaust pipe bolts to the specified torque.

"

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

• Tighten the muffler mounting nut to the specified torque.

"

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

• Tighten the footrest mounting bolts to the specified torque.

"

Footrest mounting bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

• Install the gearshift lever as shown.

2.5 mm

(0.1 in)

• After installing the engine, properly route the wire harness, cables, and hoses. Refer to the wire and cable routing sections. ( 7-13)

• Refer to the following sections to adjust the respective items to specification.

* ENGINE OIL ( 2-10)

* THROTTLE CABLE PLAY (

* ENGINE IDLE SPEED (

* DRIVE CHAIN SLACK (

2-11)

2-11)

2-13)

• Check for leakage of the engine oil.

ENGINE 3-8

3-9 ENGINE

ENGINE DISASSEMBLY

Identify the position of each removed part. Organize the parts in their respective groups so that they can be reinstalled in their original positions.

KICK STARTER LEVER

• Remove the kick starter lever.

CRANKCASE BREATHER HOSE

• Remove the crankcase breather hose.

SPARK PLUG

• Remove the spark plug.

STARTER MOTOR

• Remove the starter motor.

CYLINDER HEAD

• Remove the TDC plug 1 and generator cover plug 2 .

• Remove the camshaft sprocket cover 3 and gasket.

• Turn the crankshaft bring the “Top” line A on the generator rotor to the center of hole on the generator cover.

NOTE:

At the above condition, the piston is at TDC of compression stroke and also the mark B on the camshaft sprocket with the concave line C of the cylinder head, as shown.

ENGINE 3-10

• Remove the cam chain tension adjuster cap 4 .

3-11 ENGINE

• Hold the push rod with the screw driver.

• Remove the cam chain tension adjuster 5 .

• Remove the gasket 6 .

• Remove the camshaft sprocket washer 7 and camshaft sprocket 8 .

• Remove the cylinder head base bolt.

• Remove the cylinder head nuts diagonally.

• Remove the cylinder head nut gaskets 9 and copper washer

0 .

• Remove the cylinder head assembly A .

NOTE:

If the cylinder head does not come off easily, lightly tap it with a plastic mallet.

CYLINDER

• Remove the dowel pins 1 , cylinder head gasket 2 , O-ring 3 and cam chain guide 4 .

• Remove the cylinder base nut 5 .

• Remove the cylinder 6 .

NOTE:

If the cylinder does not come off easily, lightly tap it with a plastic mallet.

• Remove the dowel pins 7 and cylinder gasket 8 .

PISTON

• Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into the crankcase.

• Remove the piston pin circlip 1 .

• Remove the piston pin 2 and piston 3 .

NEUTRAL SWITCH

• Remove the neutral switch 1 .

• Remove the neutral switch contact 2 and spring 3 .

ENGINE 3-12

3-13 ENGINE

GENERATOR COVER

• Remove the generator cover 1 .

• Remove the dowel pins 2 and gasket 3 .

CLUTCH COVER

• Remove the clutch cover 1 .

• Remove the dowel pins 2 and gasket 3 .

OIL SUMP FILTER

• Remove the oil sump filter 1 .

OIL FILTER CASE

• Remove the oil filter cover 1 with the special tool.

09920-53740: Clutch sleeve hub holder

• Remove the oil filter case nut 2 with the special tool.

09930-44530: Rotor holder

• Remove the washer 3 and oil filter case 4 .

FIRST CLUTCH

• Remove the clutch shoe assembly 1 and primary drive gear

2 .

GEARSHIFT CLUTCH

• Remove the push piece 1 .

ENGINE 3-14

3-15 ENGINE

• Remove the snap ring 2 .

• Remove the gearshifting clutch assembly 3 .

OIL PUMP

• Remove the oil pump 1 .

• Remove the dowel pins 2 .

OIL PUMP DRIVE GEAR

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

GEARSHIFT CAM STOPPER

• Remove the gearshift cam bolt 1 and washer 2 .

• Remove the gearshift cam stopper plate 3 and gearshift cam stopper guide 4 .

• Remove the gearshift cam pins 5 .

• Remove the gearshift cam stopper 6 .

GEARSHIFT SHAFT

• Remove the release ball outer guide 1 .

• Remove the release ball 2 .

• Remove the gearshift shaft 3 and spacer 4 .

• Remove the gearshift arm assembly 5 .

ENGINE 3-16

3-17 ENGINE

• Remove the washer 6 and gearshift arm stopper 7 .

GEARSHIFT CAM RETAINER

• Remove the gearshift cam retainer 1 .

GENERATOR ROTOR AND STARTER CLUTCH

• Hold the crankshaft with the special tool.

\

09930-44530: Rotor holder

• Remove the generator rotor nut 1 .

• Remove the generator rotor 2 with the special tool.

\

09930-34951: Rotor remover

• Remove the key 3 .

• Remove the starter clutch gear plate 4 and starter driven gear 5 .

CAM CHAIN

• Remove the cam chain 1 .

STARTER IDLE GEAR

• Remove the snap ring 1 , washer 2 and starter idle gear 3 .

• Remove the starter idle gear shaft 4 .

CRANKCASE

• Remove the crankcase bolts.

• Separate the crankcase with the special tool.

\

09920-13120: Crankcase and shaft remover

NOTE:

* Fit the crankcase separating tool, so that the tool arms are in parallel with the side of crankcase.

* The crankshaft component should remain in the left crankcase half.

ENGINE 3-18

3-19 ENGINE

• Remove the dowel pins 1 .

• Remove the oil breather separator 2 .

TRANSMISSION

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

• Remove the gearshift fork No. 1 3 and No. 2 4 .

• Remove the driveshaft assembly 5 and countershaft assembly 6 .

KICK STARTER SHAFT

• Remove the washer 1 .

• Remove the kick starter shaft 2 by turning the shaft.

• Remove the kick starter guide 3 and kick starter stopper 4 .

CRANKSHAFT

• Remove the crankshaft with the special tool.

\

09920-13120: Crankcase and shaft remover

ENGINE 3-20

3-21 ENGINE

ENGINE COMPONENTS INSPECTION AND SERVICE

CYLINDER HEAD

DISASSEMBLY

Identify the position of each removed part. Organize the parts in their respective groups (i.e., intake or exhaust) so that they can be installed in their original locations.

• Remove the cam chain tensioner 1 .

• Remove the intake pipe 2 .

• Remove the valve clearance inspection caps 3 and cylinder head right cover 4 .

• Pull out the intake and exhaust rocker arm shafts 5 by using an 8-mm thread bolt.

• Remove the intake and exhaust rocker arms 6 .

• Remove the camshaft 7 .

• Compress the valve spring with the special tools.

• Remove the two cotter halves 8 .

\

09916-14510: Valve spring compressor

09916-14521: Attachment

09916-84511: Tweezers

• Remove the valve spring retainer 9 and valve spring 0 .

• Remove the valve A from the combustion chamber side.

ENGINE 3-22

3-23 ENGINE

• Remove the valve oil seal B and valve spring seat C .

ROCKER ARM SHAFT O.D.

Measure the diameter of rocker arm shaft.

Rocker arm shaft O.D. (IN. & EX.):

Standard: 9.981 – 9.990 mm (0.3930 – 0.3933 in)

\

09900-20205: Micrometer (0 – 25 mm)

ROCKER ARM I.D.

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

Rocker arm I.D. (IN. & EX.):

Standard: 10.003 – 10.018 mm (0.3938 – 0.3944 in)

\

09900-20605: Dial calipers

CYLINDER HEAD DISTORTION

Decarbonize the combustion chamber.

Inspect the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge, taking a clearance reading at several places as indicated. If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder head.

Cylinder head distortion:

Service Limit: 0.05 mm (0.002 in)

\

09900-20803: Thickness gauge

VALVE FACE WEAR

The thickness of the valve face decreases as the face wears.

Visually inspect each valve face for wear and replace any valve with an abnormally worn face. Measure the valve face thickness

T . If it is out of specification, replace the valve with a new one.

Valve head thickness (IN. & EX.):

Service Limit T : 0.5 mm (0.02 in)

\

09900-20101: Vernier calipers

VALVE STEM RUNOUT

• Support the valve using V-blocks, and check its runout with the dial gauge as shown.

• If the runout exceeds the limit, replace the valve.

Valve stem runout (IN. & EX.):

Service Limit: 0.05 mm (0.002 in)

\

09900-20701: Magnetic stand

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

09900-21304: V-block (100 mm)

Be careful not to damage the valve and valve stem when handling it.

VALVE HEAD RADIAL RUNOUT

• Place the dial gauge at right angles to the valve head, and measure the valve head radial runout.

• If it measures more than limit, replace the valve.

Valve head radial runout (IN. & EX.):

Service Limit: 0.03 mm (0.001 in)

\

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

09900-20701: Magnetic stand

09900-21304: V-block (100 mm)

Be careful not to damage the valve and valve stem when handling it.

ENGINE 3-24

3-25 ENGINE

VALVE STEM DEFLECTION

• Lift the valve about 10 mm from the valve seat.

• Measure the valve stem deflection in two directions, “X” and

“Y”, perpendicular to each other, by positioning the dial gauge as shown.

• If the deflection measured exceeds the limit, then determine whether the valve or the guide should be replaced with a new one.

Valve stem deflection:

Service Limit (IN. & EX.): 0.35 mm (0.014 in)

\

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

09900-20701: Magnetic stand

VALVE STEM WEAR

• If the valve stem is worn down to the limit, as measured with a micrometer, replace the valve.

• If the stem is within the limit, then replace the guide.

• After replacing valve or guide, be sure to recheck the deflection.

Valve stem O.D.:

Standard (IN.) : 4.960 – 4.975 mm (0.1953 – 0.1959 in)

(EX.): 4.945 – 4.960 mm (0.1947 – 0.1953 in)

\

09900-20205: Micrometer (0 – 25 mm)

NOTE:

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

VALVE GUIDE SERVICING

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

\

09916-44310: Valve guide remover/installer

NOTE:

* Discard the removed valve guide subassemblies.

* Only oversized valve guides are available as replacement parts. (Part No. 11115-02A70 (IN.), 11115-09470 (EX.))

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

\

09916-34580: Valve guide reamer (10.8 mm)

09916-34542: Reamer handle

When refinishing or removing the reamer from the valve guide hole, always turn it clockwise.

• Cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 – 150 °C (212 – 302

°F) with a hot plate.

Do not use a burner to heat the valve guide hole to prevent cylinder head distortion.

• Apply engine oil to the valve guide hole.

• Drive the valve guide into the hole with the special tool.

\

09916-44310: 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.

• After installing the valve guides, re-finish their guiding bores using the reamer.

• Clean the guides with engine oil after reaming.

\

09916-34570: Valve guide reamer (5.0 mm)

09916-34542: Reamer handle

NOTE:

* Be sure to cool down the cylinder head to ambient air temperature.

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

VALVE SEAT WIDTH INSPECTION

• Visually inspect for valve seat width on each valve face.

• If the valve face has worn abnormally, replace the valve.

• Coat the valve seat with a red lead (Prussian Blue) and set the valve in place. Rotate the valve with light pressure.

• Inspect that the transferred red lead (Prussian Blue) on the valve face is uniform all around and in center of the valve face.

\

09916-10911: Valve lapper set

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

Valve seat width W :

Standard: 0.9 – 1.1 mm (0.035 – 0.043 in)

If the valve seat is out of specification, correct the seat by servicing it as follows:

ENGINE 3-26

3-27 ENGINE

VALVE SEAT SERVICING

• The valve seats 1 for both the intake valve 2 and exhaust valve 3 are machined to three different angles. The seat contact surface is cut at 30°.

Seat angle

Seat width

Valve diameter

Valve guide I.D.

INTAKE SIDE

15°, 45°

EXHAUST SIDE

←

0.9 – 1.1 mm

(0.035 – 0.043 in)

←

22.5 mm (0.89 in) 19.0 mm (0.75 in)

5.000 – 5.012 mm

(0.1969 – 0.1973 in)

←

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

* 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 clear-

( ance after the cylinder head has been reinstalled.

2-6 and -7)

• 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

Inspect the valve stem end face for pitting and wear. If pitting or wear is present, resurface the valve stem end. Make sure that the length A is not less than 2.2 mm. If this length becomes less than 2.2 mm, replace the valve.

Valve stem end length:

Service Limit: 2.2 mm (0.09 in)

For intake and exhaust

ENGINE 3-28

VALVE SPRING INSPECTION

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

• Inspect the valve spring for proper strength by measuring its free length and also by the force required to compress it.

If the spring length is less than the service limit, or if the force required to compress the spring does not fall within the range specified, replace the spring.

Valve spring free length (IN. & EX.):

Service Limit: 34.5 mm (1.36 in)

\

09900-20102: Vernier calipers

Valve spring tension (IN. & EX.):

Standard: 157 – 181 N (16.0 – 18.5 kgf, 35.3 – 40.8 lbs) at length 25.5 mm (1.00 in)

157 – 181 N (16.0 – 18.5 kgf, 35.3 – 40.8 lbs)

25.5 mm (1.00 in)

CAM WEAR

Check the camshaft for damage or wear on the cam face. Measure the cam height H with a micrometer.

Replace the camshaft assembly if defects is found or cam height

H is less than the service limit.

Cam height H :

Service Limit (IN.) : 27.09 mm (1.067 in)

(EX.): 26.95 mm (1.061 in)

\

09900-20202: Micrometer (25 – 50 mm)

CAMSHAFT BEARING INSPECTION

Rotate the camshaft bearing outer race by finger to check for abnormal play, noise and smooth rotation.

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

RIGHT BEARING REPLACEMENT

• Remove the camshaft right bearing with the special tool.

\

09913-60910: Bearing & gear puller

If the left bearing is faulty replace the camshaft assembly.

3-29 ENGINE

• Press in the new right bearing to the camshaft with the special tool.

\

09913-70210: Bearing installer

The sealed cover of bearing must face outside.

CAM SPROCKET INSPECTION

Check the cam sprocket teeth for wear or damage. If any defects are found, replace the cam sprocket and cam chain as a set.

CAM CHAIN TENSIONER INSPECTION

Check the cam chain tensioner for wear or damage. If any defects are found, replace the cam chain tensioner with a new one.

REASSEMBLY

• Install the valve spring seat 1 .

• Apply MOLYBDENUM OIL SOLUTION to the oil seal 2 , and press-fit it into position.

P

MOLYBDENUM OIL SOLUTION

Do not reuse the removed oil seal.

• Insert the valve, with its stem coated with MOLYBDENUM

OIL SOLUTION all around and along the full stem length without any break.

When inserting valve, take care not to damage the lip of oil seal.

P

MOLYBDENUM OIL SOLUTION

• Install the valve spring with the small-pitch portion A facing cylinder head bottom.

UP ward

B Large-pitch portion

C Paint

• Be sure that the rounded lip E of the cotter fits snugly into the groove D in the stem end.

• Install the other valve and spring in the same manner as described previously.

3 Valve spring retainer

4 Cotter

\

09916-14510: Valve spring compressor

09916-14521: Attachment

09916-84511: Tweezers

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

* Be careful not to damage the valve and valve stem when handling it.

NOTE:

Just before installing the camshaft into the cylinder head, apply engine oil to the cam faces and inner rase of bearings.

• Install the intake and exhaust rocker arms 5 .

ENGINE 3-30

3-31 ENGINE

• Apply engine oil to the rocker arm shafts and rocker arms.

Install the intake rocker arm shaft 6 and exhaust rocker arm shaft 7 .

NOTE:

* Face the thread part of the rocker arm shafts to the outside.

• Install the gasket 2 and cylinder head right cover 3 to the cylinder head.

The removed gasket must be replaced with a new one.

• Tighten the cylinder head right cover bolts 4 securely.

INTAKE PIPE

• Install the intake pipe O-ring 1 .

• Apply SUZUKI SUPER GREASE “A” to the intake pipe O-ring

1 .

The removed O-ring must be replaced with a new one.

X

99000-25010: SUZUKI SUPER GREASE “A” or equivalent

• Tighten the intake pipe nuts 2 to the specified torque.

"

Intake pipe nut: 5.5 N·m (0.55 kgf-m, 4.0 lb-ft)

ENGINE 3-32

CAM CHAIN TENSIONER

• Install the cam chain tensioner 1 and washer 2 .

• Tighten the cam chain tensioner bolt 3 to the specified torque.

"

Cam chain tensioner bolt: 8 N·m (0.8 kgf-m, 6.0 lb-ft)

CYLINDER

CYLINDER DISTORTION

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

Cylinder distortion:

Service Limit: 0.05 mm (0.002 in)

\

09900-20803: Thickness gauge

CYLINDER BORE

Measure the cylinder bore diameter at six places.

If any one of the measurements exceed the limit, overhaul the cylinder and replace the piston with an oversize piston, or replace the cylinder.

Cylinder bore:

Service Limit: 48.105 mm (1.8939 in)

\

09900-20530: Cylinder bore gauge set

PISTON AND PISTON PIN

PISTON DIAMETER

Using a micrometer, measure the piston outside diameter at the place 10 mm from the piston skirt end as shown. If the measurement is less than the limit, replace the piston.

Piston diameter:

Service Limit: 47.880 mm (1.8850 in)

Piston oversize: 0.5 mm (0.02 in)

\

09900-20202: Micrometer (25 – 50 mm)

10 mm

(0.4 in)

3-33 ENGINE

PISTON TO CYLINDER CLEARANCE

• Subtract the piston diameter from the cylinder bore diameter.

• If the piston-to-cylinder clearance exceeds the service limit, rebore the cylinder and use an oversize piston or replace both the piston and cylinder.

Piston to cylinder clearance:

Service Limit: 0.120 mm (0.0047 in)

PISTON PIN AND PIN BORE

• Measure the piston pin bore diameter using the small bore gauge.

• If the measurement is out of specification, replace the piston.

Piston pin bore I.D.:

Service Limit: 13.030 mm (0.5130 in)

\

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

09900-22401: Small bore gauge (10 – 18 mm)

• Measure the piston pin outside diameter at three positions using the micrometer.

• If any of the measurements is out of specification, replace the piston pin.

Piston pin O.D.:

Service Limit: 12.980 mm (0.5110 in)

\

09900-20205: Micrometer (0 – 25 mm)

PISTON RING TO GROOVE CLEARANCE

• Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge.

• If any of the clearances exceeds the limit, replace both the piston and piston rings.

Piston ring to groove clearance:

Service Limit (1st) : 0.180 mm (0.0071 in)

(2nd): 0.150 mm (0.0059 in)

Piston ring groove width:

Standard (1st) : 1.01 – 1.03 mm (0.0398 – 0.0405 in)

(2nd): 1.21 – 1.23 mm (0.0476 – 0.0484 in)

(Oil) : 2.01 – 2.03 mm (0.0791 – 0.0799 in)

Piston ring thickness:

Standard (1st) : 0.97 – 0.99 mm (0.0382 – 0.0390 in)

(2nd): 1.16 – 1.18 mm (0.0457 – 0.0465 in)

\

09900-20205: Micrometer (0 – 25 mm)

09900-20803: Thickness gauge

NOTE:

Using a soft-metal scraper, decarbon the crown of the piston.

Clean the ring grooves similarly.

ENGINE 3-34

PISTON RING FREE END GAP AND PISTON RING END GAP

• Measure the piston ring free end gap using the vernier calipers.

• Next, fit the piston ring squarely into the cylinder and measure the piston ring end gap using the thickness gauge.

• If any of the measurements exceeds the service limit, replace the piston ring with a new one.

Piston ring free end gap:

Service Limit (1st) : 4.0 mm (0.16 in)

(2nd): 5.3 mm (0.21 in)

\

09900-20102: Vernier calipers

Piston ring end gap:

Service Limit (1st & 2nd) : 0.5 mm (0.02 in)

\

09900-20803: Thickness gauge

OVERSIZE RING

Oversize piston ring

The following oversize piston ring is used. It bears the following identification number.

Piston ring 1st and 2nd 0.5 mm: 50

Oversize oil ring

The following oversize oil ring is used. It bears the following identification mark.

Oil ring 0.5 mm: Painted red

Oversize side rail

Measure the outside diameter to identify the size.

CAM CHAIN TENSION ADJUSTER

INSPECTION

Check the push rod movement. If the push rod is stuck or spring mechanism fails, replace the cam chain tension adjuster with a new one.

Paint

0.5 mm O.S.

Oil ring spacer

3-35 ENGINE

CAM CHAIN GUIDE

INSPECTION

Check the cam chain guide for wear or damage. If any defects are found, replace the cam chain guide with a new one.

CONROD AND CRANKSHAFT

ENGINE 3-36

1

2

Oil pump drive gear

Crankshaft, RH

3

4

Crankshaft, LH

Conrod

CONROD SMALL END I.D.

Using a caliper gauge, measure the conrod small end inside diameter.

Conrod small end I.D.:

Service Limit: 13.040 mm (0.5134 in)

\

09900-20605: Dial calipers

If the conrod small end bore inside diameter exceeds the limit, replace the conrod.

5

6

Bearing

Crank pin

3-37 ENGINE

CONROD DEFLECTION AND CONROD BIG END SIDE

CLEARANCE

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

Push the big end of the conrod to one side and measure the side clearance using a thickness gauge.

If the clearance exceeds the service limit, replace crankshaft assembly or bring the deflection and side clearance into specification by replacing the worn parts. (e.g., conrod, big end bearing and crank pin)

Conrod big end side clearance

Service Limit: 1.0 mm (0.04 in)

\

09900-20803: Thickness gauge

CRANKSHAFT RUNOUT

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

Crankshaft runout

Service Limit: 0.08 mm (0.003 in)

\

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

09900-20701: Magnetic stand

09900-21304: V-block

NOTE:

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

* Measure the runout from the tips of the crankshaft.

REASSEMBLY

• When rebuilding the crankshaft, the width between the webs

A should be within the standard range.

Crank web-to-web width A :

Standard: 38.0 ± 0.1 mm (1.496 ± 0.004 in)

OIL PUMP

DISASSEMBLY

• Remove the O-rings 1 .

• Remove the circlip 2 , washer 3 , oil pump driven gear 4 and pin 5 .

INSPECTION

Rotate the oil pump shaft by finger and check for abnormal play, noise and smooth rotation.

If there is anything unusual, replace the oil pump.

Do not attempt to disassemble the oil pump assembly.

It is available only as an assembly.

REASSEMBLY

• Reassemble the oil pump in the reverse order of disassembly.

Apply SUZUKI SUPER GREASE “A” to the O-rings 1 .

X

99000-25010: SUZUKI SUOER GREASE “A” or equivalent

• Install the O-rings 1 .

The removed O-rings must be replaced with new ones.

OIL SUMP FILTER

• Clean the oil sump filter with compressed air.

ENGINE 3-38

3-39 ENGINE

TRANSMISSION

DISASSEMBLY

• Disassemble the transmission gears as shown in the illustration.

1

2

3

1st driven gear

3rd driven gear

Driveshaft

4

5

6

Countershaft

3rd drive gear

Sliding dog

7 2nd drive gear

REASSEMBLY

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

NOTE:

Before installing the gears, apply engine oil to the bearing and inner surface of the each gear.

* 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, do not expand the end gap larger than required to slip the snap ring over the shaft.

* After installing a snap ring, make sure 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 the snap ring to the side where the thrust is as shown in the illustration. The rounded side should be against the gear surface.

Thrust

ENGINE 3-40

Sharp edge

1 Countershaft

2 Driveshaft

3-41 ENGINE

GEARSHIFT CAM

Inspect the gearshift cam wear or damage.

If any defects are found, replace the gearshift cam with a new one.

GEARSHIFT FORKS

GEARSHIFT FORK-TO-GROOVE CLEARANCE

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

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

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

Gearshift fork-to-groove clearance

Service Limit (No, 1 & No, 2): 0.5 mm (0.02 in)

\

09900-20803: Thickness gauge

GEARSHIFT FORK GROOVE WIDTH

• Measure the gearshift fork groove width using the vernier calipers.

Gearshift fork groove width

Standard

(No. 1 & No. 2): 4.5 – 4.6 mm (0.177 – 0.181 in)

\

09900-20101: Vernier calipers

GEARSHIFT FORK THICKNESS

• Measure the gearshift fork thickness using the vernier calipers.

Gearshift fork thickness

Standard

(No. 1 & No. 2): 4.3 – 4.4 mm (0.169 – 0.173 in)

\

09900-20101: Vernier calipers

GEARSHIFTING CLUTCH

CONSTRUCTION

ENGINE 3-42

1

2

3

Push piece

Clutch sleeve hub

Clutch driven plate No.1

4

5

6

Clutch driven plate No.2

Primary driven gear

Clutch drive plate

DISASSEMBLY

• Campress the clutch spring using the special tool and remove the snap ring 1 .

\

09920-33510: Clutch spring campressor

7

8

Clutch pressure plate

Clutch spring

CLUTCH DRIVE AND DRIVEN PLATE INSPECTION

Measure the thickness and claw width of the clutch drive and driven plates using vernier calipers. If a clutch drive and/or driven plate is not within the service limit, replace it with a new one.

Clutch drive and driven plate thickness

Service Limit (drive) A : 2.2 mm (0.092 in)

(driven No.1) B : 1.72 mm (0.068 in)

(driven No.2) C : 2.2 mm (0.092 in)

\

09900-20101: Vernier calipers

3-43 ENGINE

Clutch drive and driven plate claw width

Service Limit (drive): 15.15 mm (0.596 in)

(driven): 11.3 mm (0.44 in)

\

09900-20101: Vernier calipers

REASSEMBLY

Reassemble the gearshifting clutch in the reverse order of disassembly. Pay attention to the following points:

• Align the claw 1 of clutch driven plate No.1 2 with the boss

3 of clutch sleeve hub.

• Align the claw 5 of clutch driven plate No.2 4 with the groove 6 of clutch sleeve hub.

• Face the boss of primary driven gear 7 to upper when installing it.

• Align the claw 8 of clutch driven plate No.1 with the hole 9 of primary driven gear.

• Install the clutch driven plate No.1 9 .

• When installing the clutch drive plate 0 , face its claw A downward as shown.

• Install the clutch pressure plate B .

• Install the clutch spring C and spacer D .

• Compress the spring with the special tool and install the snap ring 1 .

\

09920-33510: Clutch spring compressor

The removed snap ring must be replaced with a new one.

ENGINE 3-44

3-45 ENGINE

FIRST CLUTCH

CLUTCH SHOES INSPECTION

Inspect the clutch shoes for chips, cracks, uneven wear and burning. Check the depth of grooves on the shoe. If there in no groove at any part of the shoe, replace the clutch shoe assembly.

Clutch shoe thickness

Service Limit: No groove at any part

Inspect the clutch springs for stretched or broken coils. If any defects are found, replace the clutch shoe assembly.

CLUTCH WHEEL INSPECTION

Inspect the first clutch housing surface for scrolling, cracks, or uneven wear and measure the inside diameter of the clutch housing with inside calipers. Measure the diameter at several points to check for out-of-roundness and wear. If any defects are found or if the inside diameter exceeds the service limit, replace the first clutch housing with a new one.

First clutch housing l.D.

Service Limit: 105.50 mm (4.154 in)

Inspect each roller and one way clutch retainer for abnormal wear or damage.

If any defects are found, replace them as a set.

1 First clutch housing

2 Primary drive gear spacer

3 Washer

4 One way clutch retainer

5 One way clutch spring

6 One way clutch roller

7 One way clutch inner race

STARTER CLUTCH

INSPECTION OF STARTER CLUTCH OPERATION

Turn the starter driven gear by hand in the direction of arrow as shown and check that rotation is smooth. Also check that the gear is locked when attempted to turn in the other direction.

If a large resistance is felt or noise occurs when turning the gear, check the starter driven gear sliding surface for wear or damage.

If any abnormal condition is found, replace the starter clutch with a new one.

DISASSEMBLY

• Remove the starter driven gear.

• Holding the generator rotor with the special tool, remove the starter clutch bolts 1 .

\

09930-44530: Rotor holder

• Remove the starter clutch 2 from the rotor.

INSPECTION

Inspect the starter clutch for damage and excessive wear. If any defects are found, replace the starter clutch with a new one.

Inspect the starter driven gear for wear or damage. If any defects are found, replace the starter driven gear with a new one.

REASSEMBLY

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

• Install the starter clutch in the proper direction as shown.

• Apply engine oil to the starter clutch.

• Apply THREAD LOCK SUPER “1322” to the bolts.

H

99000-32110: THREAD LOCK SUPER “1322”

• Holding the generator rotor with the special tool, tighten the starter clutch bolts 1 to the specified torque.

"

Starter clutch bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

\

09930-44530: Rotor holder

ENGINE 3-46

3-47 ENGINE

GENERATOR COVER

DISASSEMBLY

• Remove the generator lead wire clamp 1 , stator coil 2 , pick-up coil 3 and grommet 4 .

REASSEMBLY

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

• Tighten the generator stator bolts 1 , pick-up coil set bolts 2 and generator lead wire clamp bolt 3 to the specified torque.

"

Generator stator bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

Pick-up coil set bolt: 4.5 N·m (0.45 kgf-m, 3.5 lb-ft)

Generator lead wire clamp bolt:

10 N·m (1.0 kgf-m, 7.0 lb-ft)

NOTE:

Be sure to install the grommet 4 to the generator cover.

CLUTCH COVER

DISASSEMBLY

• Remove the lock-nut 1 and spacer 2 .

• Remove the release arm 3 .

• Remove the O-ring 4 .

• Remove the oil seal 5 .

• Remove the oil seal 6 with the special tool.

\

09913-50121: Oil seal remover

REASSEMBLY

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

• Install the oil seal 1 and 2 with the special tool.

\

09913-70210: Bearing installer set

The removed oil seals must be replaced with new ones.

• Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal.

X

99000-25010: SUZUKI SUPER GREASE “A” or equivalent

• Install the O-ring 3 .

The removed O-ring must be replaced with a new one.

ENGINE 3-48

3-49 ENGINE

• When installing the release arm 4 align the tongue A of release arm plate with the groove B .

• Install the spacer 5 and lock-nut 6 and tighten the lock-nut

6 .

CRANKCASE

BEARING INSPECTION

• Rotate the 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.

RIGHT CRANKCASE BEARING REMOVAL

• Remove the bearing retainer 1 .

• Remove the bearings with the special tools.

\

09921-20240: Bearing remover set

Bearing 2 :

¬

22 Attachment

Bearing 3 :

¬

17 Attachment

Bearing 4 :

¬

12 Attachment

LEFT CRANKCASE BEARING REMOVAL

• Remove the bearings with the special tools.

\

09921-20240: Bearing remover set

Bearing 1 :

¬

62 Attachment

Bearing 2 :

¬

17 Attachment

Bearing 3 :

¬

40 Attachment

LEFT CRANKCASE OIL SEAL REMOVAL

• Remove the oil seals 1 with the special tool.

\

09913-50121: Oil seal remover

RIGHT CRANKCASE BEARING INSTALLATION

• Install the bearings with the special tool.

\

09913-70210: Bearing installer set

Bearing 1 :

¬

52 Attachment

Bearing 2 :

¬

40 Attachment

Bearing 3 :

¬

35 Attachment

NOTE:

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

The removed bearings must be replaced with new ones.

• Apply a small quantity of THREAD LOCK SUPER “1322” to the bearing retainer screws.

H

99000-32050: THREAD LOCK SUPER “1322”

• Tighten the screws 4 securely.

ENGINE 3-50

3-51 ENGINE

LEFT CRANKCASE BEARING INSTALLATION

• Install the bearings with the special tool.

Bearing 1 :

¬

62 Attachment

Bearing 2 :

¬

17 Attachment

Bearing 3 :

¬

40 Attachment

NOTE:

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

The removed bearings must be replaced with new ones.

\

09913-70210: Bearing installer set

LEFT CRANKCASE OIL SEAL INSTALLATION

• Install the oil seals 1 to the left crankcase with the special tool.

• Apply SUZUKI SUPER GREASE “A” to the oil seal lip.

X

99000-25010: SUZUKI SUPER GREASE “A” or equivalent

\

09913-70210: Bearing installer set

The removed oil seals must be replaced with new ones.

ENGINE REASSEMBLY

Reassemble the engine in the reverse order of disassembly.

The following steps require special attention or precautionary measures should be taken.

NOTE:

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

CRANKSHAFT

• When installing the crankshaft into the left crankcase, it is necessary to pull its left end into the left crankcase with the special tools.

\

09910-32812: Crankshaft installer

09910-32860: Crankshaft installer spacer

09911-11310: Attachment

Never fit the crankshaft into the crankcase by striking it with a plastic mallet. Always use the special tool, otherwise the accuracy of crankshaft alignment will be affected.

CRANKSHAFT SHIM SELECTION

• Degrease the right crankshaft web, shim and inner race of the right crankshaft bearing.

• Place the removed shim 1 on the right crankshaft.

• Put the plasti-gauge (special tool) 2 cut out about 10 mm on the shim as shown.

\

09900-22301: Plasti-gauge

• Install the right crankcase and tighten the crankcase bolts to the specified torque.

"

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

Never rotor the crankshaft when a piece of plastigauge is installed.

• Remove the crankcase bolts.

• Separate the crankcase with the special tool. ( 3-18)

• Measure the width of compressed plasti-gauge with the envelope scale.

Crankshaft thrust clearance:

0.02 to 0.07 mm (0.0008 – 0.0027 in)

ENGINE 3-52

3-53 ENGINE

• If the thrust clearance is not within specification, measure the thickness of shim with a micrometer and select the proper size of shim shown below.

• The shim size is printed on the shim surface.

• After selecting the proper size of shim, place it on the right crankshaft.

LIST OF SHIMS

Part number

09181-20187

09181-20009

09181-20188

09181-20189

09181-20190

09181-20191

09181-20192

09181-20193

09181-20195

09181-20197

09181-20200

09181-20202

09181-20204

09181-20207

09181-20209

Shim thickness

0.60 mm (0.024 in)

0.65 mm (0.026 in)

0.70 mm (0.028 in)

0.75 mm (0.030 in)

0.80 mm (0.031 in)

0.85 mm (0.033 in)

0.90 mm (0.035 in)

0.95 mm (0.037 in)

1.00 mm (0.039 in)

1.05 mm (0.041 in)

1.10 mm (0.043 in)

1.15 mm (0.045 in)

1.20 mm (0.047 in)

1.25 mm (0.049 in)

1.30 mm (0.051 in)

ENGINE 3-54

KICK STARTER

1

2

Kick starter lever

Kick starter drive gear

3

4

Kick starter shaft

Kick starter

• Install the kick starter stopper 1 and kick starter guide 2 .

5 Kick starter return spring

• Align the punched mark A on the kick starter with the punched mark B on the kick starter shaft.

3-55 ENGINE

• Install the kick starter return spring 1 , kick starter shaft 2 and kick starter spring hook end 3 onto the left crankcase boss.

TRANSMISSION

• Install the countershaft assembly 1 and driveshaft assembly

2 .

• Install the gearshift forks.

• Install the gearshift cam 5 .

3 : Gearshift fork No. 1

4 : Gearshift fork No. 2

• Install the gearshift fork shafts 6 .

 

OIL BREATHER SEPARATOR

• Install the oil breather separator.

NOTE:

When installing the oil breather separator, do not make the breather separator came out of the matching surface.

CRANKCASE

• Thoroughly remove the sealant material and oil stains on the mating surface of the right and left crankcases.

• Install the dowel pins 1 into the left half of the crankcase.

• Apply engine oil to the conrod big end and transmission gears.

• Apply SUZUKI BOND “1215” to the mating surface of the right crankcase as shown.

E

99000-31110: SUZUKI BOND “1215”

• Tighten the crankcase bolts to the specified torque.

"

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

NOTE:

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

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

ENGINE 3-56

3-57 ENGINE

STARTER IDLE GEAR

• Install the starter idle gear shaft 1 .

• Install the starter idle gear 2 , washer 3 and snap ring 4 .

NOTE:

Apply engine oil to the starter idle gear and shaft.

Removed snap ring must be replaced with a new one.

CAM CHAIN

• Install the cam chain 1 onto the crankshaft sprocket.

STARTER CLUTCH AND GENERATOR ROTOR

• Apply engine oil to the starter driven gear bearing 1 and crankshaft 2 .

• Install the starter driven gear 3 , key 4 and starter clutch gear plate 5 .

NOTE:

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

• Install the generator rotor 6 .

• Hold the generator rotor 6 with the special tool.

• Tighten the generator rotor nut 7 to the specified torque.

\

09930-44530: Rotor holder

"

Generator rotor nut: 55 N·m (5.5 kgf-m, 40.0 lb-ft)

GEARSHIFT

ENGINE 3-58

5

6

7

8

1

2

3

4

Gearshift cam guide

Gearshift cam plate

Gearshift pin

Gearshift cam

Gearshift stopper

Gearshift fork No.1

Gearshift fork No.2

Neutral switch

C

D

A

9

0

A

B

Release arm

Release ball outer guide

Release ball

Gearshift shaft

Gearshift arm lever

Gearshift lever

Gearshift arm stopper bolt

"

ITEM

A

N·m kgf-m

19 1.9

lb-ft

13.5

3-59 ENGINE

GEARSHIFT CAM RETAINER

• Install the gearshift cam retainer.

GEARSHIFT SHAFT

• Apply THREAD LOCK SUPER “1322” to the gearshift arm stopper bolt 1 and tighten it to the specified torque.

H

99000-32110: THREAD LOCK SUPER “1322”

"

Gearshift arm stopper bolt: 19 N·m (1.9 kgf-m, 13.5 lb-ft)

• Install the washer 2 , gearshift arm assembly 3 , gearshift spacer 4 and gearshift shaft 5 .

• Install the release ball 6 .

NOTE:

Face the lug A of the release ball 6 to the outside.

• Install the release ball outer guide 7 as shown.

GEARSHIFT CAM STOPPER

• Install the gearshift cam pins 1 .

• Install the gearshift cam plate 2 and gearshift cam guide 3 .

• Install the washer 4 and gearshift cam bolt 5 .

• Install the washer 1 , return spring 2 , gearshift cam stopper

3 , gearshift cam stopper bolt 4 .

OIL PUMP AND DRIVE GEAR

• Install the pin 1 and oil pump drive gear 2 .

• Install the dowel pins 3 .

• Apply SUZUKI SUPER GREASE “A” to the O-rings 4 .

• Install the O-rings 4 .

X

99000-25010: SUZUKI SUPER GREASE “A” or equivalent

The removed O-rings must be replaced with new ones.

ENGINE 3-60

3-61 ENGINE

• Install the oil pump 5 .

GEARSHIFTING CLUTCH

• Install the gearshifting clutch assembly 1 .

• Install the snap ring 2 .

The removed snap ring must be replaced with a new one.

• Install the clutch push piece 3 .

FIRST CLUTCH AND OIL FILTER CASE

ENGINE 3-62

1

2

3

Oil filter cover

Oil filter case

Clutch shoe assembly

4

A

Primary drive gear

Oil filter case nut

FIRST CLUTCH

• Install the clutch shoe assembly 1 with its grooves A diagonally to the crankshaft oil hole B as shown.

"

ITEM

A

N·m

63 kgf-m

6.3

lb-ft

45.5

OIL FILTER CASE

• Install the oil filter case 1 .

Align the crankshaft oil hole B with the oil filter case groove A .

3-63 ENGINE

• Install the O-ring 2 and washer 3 .

• Apply SUZUKI SUPER GREASE “A” to the O-ring 2 .

X

99000-25010: SUZUKI SUPER GREASE “A” or equivalent

The removed O-ring must be replaced with a new one.

NOTE:

Install the washer 3 as shown in the illustration.

• Hold the generator rotor with the special tool.

• Tighten the oil filter case nut 4 to the specified torque.

\

09930-44530: Rotor holder

"

Oil filter case nut: 63 N·m (6.3 kgf-m, 45.5 lb-ft)

• Install the oil filter case cover 5 using the special tool.

\

09920-53740: Clutch sleeve hub holder

OIL SUMP FILTER

• Install the oil sump filter.

* The lip A of the oil sump filter should be positioned downward.

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

CLUTCH COVER

• Install the dowel pins 1 and gasket 2 .

The removed gasket must be replaced with a new one to prevent oil leakage.

• Install the clutch cover 3 and tighten its bolts to the specified torque.

"

Clutch cover bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

CLUTCH ADJUSTMENT

• Loosen the lock-nut 1 .

• First, turn the release screw 2 clockwise by one turn and turn it counterclockwise until resistance is felt, then turn it clockwise by 1/8 turn.

• Tighten the lock-nut 1 while holding the release screw 2 .

GENERATOR COVER

• Install the dowel pins 1 and gasket 2 .

The removed gasket must be replaced with a new one to prevent oil leakage.

• Install the generator cover 3 .

• Tighten the generator cover bolts to the specified torque.

"

Generator cover bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

NOTE:

Install the lead wire clamp with the bolt A .

ENGINE 3-64

3-65 ENGINE

NEUTRAL SWITCH

• Install the spring 1 and neutral switch contact 2 .

• Apply SUZUKI SUPER GREASE “A” to the O-ring 3 .

X

99000-25010: SUZUKI SUPER GREASE “A” or equivalent

• Install the neutral switch 4 .

The removed O-ring must be replaced with a new one.

PISTON RING

• Install the piston rings in the order of oil ring, 2nd ring and 1st ring.

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

* When installing the spacer, be careful so that the both edges are not overlapped.

* When installing the piston rings, be careful not to damage the piston.

* Do not expand the piston ring excessively since it is apt to be broken down.

INCORRECT

CORRECT

• Install the 2nd ring and 1st ring.

NOTE:

2nd ring and 1st ring differ in shape.

1st

2nd

ENGINE 3-66

• Face the stamped mark upward when assembling.

• Position the gaps of the three rings as shown.

NOTE:

Before inserting piston into the cylinder, check that the gaps are so located.

•

2nd ring

•

Lower side rail

•

Upper side rail

•

1st ring

•

Spacer

PISTON

• Apply a small quantity of MOLYBDENUM OIL SOLUTION onto the piston pin.

P

MOLYBDENUM OIL SOLUTION

NOTE:

Install the piston with the mark A on the piston head facing towards the exhaust side.

• Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into the crankcase.

• Install the circlip 1 .

NOTE:

The circlip end gap should not be aligned with the piston pin bore cutaway.

The removed circlip must be replaced with a new one.

3-67 ENGINE

CYLINDER

• Apply engine oil to the sliding surface of the piston, piston rings, conrod big end and cylinder wall.

• Install the dowel pins 1 and cylinder gasket 2 .

The removed gasket must be replaced with a new one.

• Install the cylinder 3 .

NOTE:

When installing the cylinder, keep the cam chain taut. The cam chain must not be caught between the cam chain drive sprocket and crankcase when the crankshaft is rotated.

CYLINDER HEAD

• Install the dowel pins 1 , cylinder head gasket 2 and O-ring

3 .

The removed gasket and O-ring must be replaced with a new one.

• Install the cam chain guide 4 .

• Install the cylinder head assembly 5 after hang the cam chain to the camshaft flange.

• Install the cylinder head washers 6 and copper washer 7 .

• Tighten the cylinder head nut diagonally to the specified torque.

"

Cylinder head nut: 11 N·m (1.1 kgf-m, 8.0 lb-ft)

• Tighten the cylinder nut 8 and cylinder head bolt 9 to the specified torque.

"

Cylinder head bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

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

CAMSHAFT SPROCKET

• Turn the crankshaft until the “Top” line A on the generator rotor is aligned with the center of the hole in the generator cover.

• Install the camshaft sprocket 1 .

• Engage the cam chain onto the camshaft sprocket.

• Align the mark B of the cam sprocket with the concave line C of the cylinder head.

• Tighten the camshaft sprocket bolts 2 to the specified torque.

"

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

CAM CHAIN TENSION ADJUSTER

• Apply engine oil to the push rod.

• Turn the adjusting screw clockwise with a screwdriver until the push rod is locked.

ENGINE 3-68

3-69 ENGINE

• Install the gasket 1 .

The removed gasket must be replaced with a new one.

• Tighten the cam chain tension adjuster mounting bolts to the specified torque.

"

Cam chain tension adjuster bolt:

10 N·m (1.0 kgf-m, 7.0 lb-ft)

NOTE:

Make sure that the “up” mark comes to the engine upper side.

• Turn the adjusting screw counter clockwise with a screw driver to unlock.

• Install the rubber cap 3 .

• After installing the cam chain tension adjuster, rotate the crankshaft (some turns), and recheck the positions of the camshaft sprocket.

Be sure to check the valve clearance. ( 2-6 and -7)

VALVE CLEARANCE INSPECTION CAP AND

CAMSHAFT SPROCKET COVER

• Apply SUZUKI SUPER GREASE “A” to the O-ring.

X

99000-25010: SUZUKI SUPER GREASE “A” or equivalent

The removed O-ring must be replaced with a new one.

• Apply SUZUKI SUPER GREASE “A” to the O-ring.

X

99000-25010: SUZUKI SUPER GREASE “A” or equivalent

The removed O-ring must be replaced with a new one.

“up”

Upper side

TDC PLUG AND GENERATOR COVER CAP

• Apply SUZUKI SUPER GREASE “A” to the generator cover plug O-ring 1 .

X

99000-25030: SUZUKI SUPER GREASE “A” or equivalent

• Tighten the generator cover plug 2 and TDC plug 3 to the specified torque.

The removed O-ring must be replaced with a new one.

"

Generator cover plug: 11 N·m (1.1 kgf-m, 8.0 lb-ft)

TDC plug: 11 N·m (1.1 kgf-m, 8.0 lb-ft)

STARTER MOTOR

• Install the O-ring 1 to the starter motor.

• Apply SUZUKI SUPER GREASE “A” to the O-ring 1 .

X

99000-25010: SUZUKI SUPER GREASE “A” or equivalent

The removed O-ring must be replaced with a new one.

• Install the starter motor 2 to the engine.

• Tighten the starter motor mounting bolts to the specified torque.

"

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

KICK STARTER LEVER

• Install the kick starter lever 1 .

35˚

ENGINE 3-70

4-1 FUEL SYSTEM

FUEL SYSTEM

CONTENTS

FUEL TANK AND FUEL VALVE ...................................................................4- 2

CONSTRUCTION ....................................................................................4- 2

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

FUEL FILTER INSPECTION AND CLEANING ......................................4- 3

FUEL HOSE INSPECTION .....................................................................4- 4

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

CARBURETOR ..............................................................................................4- 5

CONSTRUCTION ....................................................................................4- 5

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

I.D. NO. LOCATION ................................................................................4- 6

REMOVAL ...............................................................................................4- 6

DISASSEMBLY .......................................................................................4- 7

CLEANING ..............................................................................................4- 9

INSPECTION AND ADJUSTMENT.........................................................4-10

REASSEMBLY AND REMOUNTING......................................................4-11

LUBRICATION SYSTEM ...............................................................................4-13

OIL PRESSURE ......................................................................................4-13

OIL FILTER CASE ..................................................................................4-13

OIL SUMP FILTER ..................................................................................4-13

OIL PUMP................................................................................................4-13

ENGINE LUBRICATION SYSTEM CHART ............................................4-13

#

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

FUEL TANK AND FUEL VALVE

CONSTRUCTION

FUEL SYSTEM 4-2

4

6

1

2

3

Fuel tank breather hose

Fuel tank cap

Fuel tank

4

5

A

Fuel valve

Fuel hose

Fuel valve bolt

"

ITEM N·m kgf-m lb-ft

A 4.5

0.45

3.0

4-3 FUEL SYSTEM

REMOVAL

#

* Gasoline is highly flammable and explosive.

* Keep heat, spark and flame away.

• Remove the seat and fuel tank side covers. ( 5-3)

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

• Disconnect the fuel hose 1 from the fuel valve.

• Remove the fuel tank 2 .

• Remove the fuel tank cap 3 and fuel tank upper cover 4 .

• Remove the fuel valve 5 .

FUEL FILTER INSPECTION AND CLEANING

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

Clean the fuel filter with compressed air and check the fuel filter for cracks.

 

(

FUEL HOSE INSPECTION

2-9)

REMOUNTING

Remount the fuel tank and fuel valve in the reverse order of removal. Pay attention to the following points:

• Install the new fuel valve gasket 1 .

#

The removed gasket must be replaced with a new one to prevent fuel leakage.

• Tighten the fuel valve bolts to the specified torque.

"

Fuel valve bolt: 4.5 N·m (0.45 kgf-m, 3.5 lb-ft)

• Install the fuel tank and tighten its bolts securely.

• Install the fuel hose and fuel tank breather hose. ( 7-15)

• Reinstall the seat and fuel tank cover. ( 5-3)

FUEL SYSTEM 4-4

4-5 FUEL SYSTEM

CARBURETOR

CONSTRUCTION

5

6

7

8

1

2

3

4

Carburetor top cap

Gasket

Spring

Spring seat

O-ring

Jet needle

Throttle valve

Starter plunger

C

D

E

F

9

0

A

B

O-ring

Air screw

O-ring

Throttle stop screw

Needle valve seat

Needle

Needle jet

Needle jet holder

K

L

M

N

G

H

I

J

Main jet

Pilot jet

Float

Gasket

Float chamber

Overflow hose

Drain plug

Air vent hose

SPECIFICATIONS

ITEM

Carburetor type

Bore size

I.D. No.

Idle r/min

Float height

Main jet (M.J)

Jet needle (J.N)

Needle jet (N.J)

Pilot jet (P.J)

Air screw (A.S)

Throttle cable play

SPECIFICATION

MIKUNI VM13SH

13 mm (0.5 in)

14H0

1 600 ± 100 r/min

23.4 ± 1.0 mm (0.92 ± 0.04 in)

#55

3L43

E-5M

#17.5

PRE-SET (2 turns back)

2.0 – 4.0 mm (0.08 – 0.16 in)

I.D. NO. LOCATION

• The carburetor has I.D. Number A stamped on the carburetor body.

FUEL SYSTEM 4-6

REMOVAL

• Remove the seat. ( 5-2)

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

• Remove the exhaust pipe cover. ( 2-19)

• Loosen the drain plug 1 and drain the fuel from the carburetor.

#

Gasoline is highly flammable and explosive.

Keep heat, spark and flame away.

• Disconnect the carburetor top cap 2 .

• Disconnect the starter cable 3 .

• Loosen the intake pipe clamp screw 4 .

• Remove the carburetor mounting bolts/nuts 5 .

• Remove the carburetor assembly 6 .

4-7 FUEL SYSTEM

DISASSEMBLY

• Remove the starter plunger 1 .

• Remove the throttle valve 2 and spring 3 from the throttle cable.

• Remove the spring seat 4 .

• Remove the jet needle 5 , washer 6 and spring 7 from the throttle valve 2 .

• Remove the air vent hose 7 and overflow hose 8 .

• Remove the float chamber 9 .

• Remove the gasket 0 .

• Remove the float pin A .

• Remove the float B .

• Remove the needle valve C .

• Remove the needle valve seat D .

• Remove the main jet E , needle jet holder F and needle jet

G .

• Remove the pilot jet H .

FUEL SYSTEM 4-8

• Remove the throttle stop screw I .

• Remove the O-ring J , washer K and spring L from the throttle stop screw I .

4-9 FUEL SYSTEM

AIR SCREW REMOVAL

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 air screw plug. Set the drill-stop 6 mm from the end of the bit to prevent drilling into the air 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 air screw in clockwise and count the number of turns until the screw is lightly seated. Make a note of how many turns were made so the screw can be reset correctly after cleaning.

• Remove the air screw with the spring, washer, and O-ring.

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

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

CLEANING

#

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

Drill-stop

Air screw

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

• Clean all circuits of the carburetor thoroughly – not just the perceived problem area. Clean the circuits in the carburetor body with a spray-type cleaner and allow each circuit to soak, if necessary, to loosen dirt and varnish. Blow the body with compressed air.

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

Plug

Carburetor body

INSPECTION AND ADJUSTMENT

CARBURETOR PARTS

Check the following items for any damage or clogging.

If they are clogged, clean the fuel passage.

* Pilot jet

* Main jet

* Starter plunger

* Float

* Throttle valve

* Needle valve seat

* Needle jet bleeding hole

* Gasket and O-rings

* Pilot passageway

* Starter passageway

* Needle jet

* Needle jet holder

* Throttle stop screw

* Needle valve

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 needle valve is worn beyond the permissible limit, 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 in the illustration, replace the needle valve assembly with a new one. Clean the fuel passage of the mixing chamber with 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 with vernier calipers.

NOTE:

When measuring the float height, remove the gasket.

Float height A : 23.4 ± 1.0 mm (0.92 ± 0.04 in)

\

09900-20102: Vernier calipers

• If the float height A is out of specification, bend the float arm

1 to bring the float height A to the standard range.

• After adjusting, check the float height A .

FUEL SYSTEM 4-10

4-11 FUEL SYSTEM

REASSEMBLY AND REMOUNTING

Reassemble and install the carburetor in the reverse order of removal and disassembly. Pay attention to the following points:

• Install the needle valve seat 1 .

The removed O-ring must be replaced with a new one.

• Install the throttle stop screw 2 .

The removed O-rings must be replaced with new ones.

• Install the gasket 3 .

The removed gasket must be replaced with a new one.

• Install the throttle valve 4 to the carburetor.

Align the slit B of the throttle valve 4 with the projection C on the carburetor body.

• Install the O-rings 5 .

• Apply SUZUKI SUPER GREASE “A” to the O-rings 5 .

X

99000-25010: SUZUKI SUPER GREASE “A” or equivalent

The removed O-rings must be replaced with new ones.

• Tighten the intake pipe clamp screw 6 .

• Tighten the carburetor mounting bolts 7 to the specified torque.

"

Carburetor mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

• After remounting the carburetor, perform the following:

* Install the fuel hose. .................................. 7-15

* Check for fuel leakage.

* Engine idle r/min adjustment ..................... 2-11

* Throttle cable play adjustment .................. 2-11

FUEL SYSTEM 4-12

4-13 FUEL SYSTEM

LUBRICATION SYSTEM

OIL PRESSURE

2-19

OIL FILTER CASE

3-14

OIL SUMP FILTER

3-38

OIL PUMP

3-38

ENGINE LUBRICATION SYSTEM CHART

CAM FACE CAMSHAFT CAM CHAIN

INTAKE

ROCKER

ARM

EXHAUST

ROCKER

ARM

CYLINDER

HEAD

CONROD

SMALL

END

CYLINDER

OIL ORIFICE

OIL PUMP

CLUTCH COVER

OIL FILTER

CASE

CRANKSHAFT

CYLINDER

WALL

CONROD

BIG END

BEARING

OIL SUMP

FILTER

PRIMARY

DRIVE

GEAR

FIRST

CLUTCH

CHASSIS

CONTENTS

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

FASTENER REMOVAL AND INSTALLATION .....................................5- 2

REMOVAL ..............................................................................................5- 2

REASSEMBLY .......................................................................................5- 3

FRONT WHEEL AND FRONT BRAKE ........................................................5- 4

CONSTRUCTION ...................................................................................5- 4

REMOVAL ..............................................................................................5- 4

INSPECTION AND DISASSEMBLY ......................................................5- 6

REASSEMBLY .......................................................................................5- 7

REMOUNTING .......................................................................................5- 9

FRONT FORK ...............................................................................................5-10

CONSTRUCTION ...................................................................................5-10

REMOVAL ..............................................................................................5-11

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

REASSEMBLY AND REMOUNTING ....................................................5-13

STEERING ....................................................................................................5-15

CONSTRUCTION ...................................................................................5-15

REMOVAL AND DISASSEMBLY ..........................................................5-15

INSPECTION ..........................................................................................5-17

REASSEMBLY AND REMOUNTING ....................................................5-18

REAR WHEEL AND REAR BRAKE ............................................................5-21

CONSTRUCTION ...................................................................................5-21

REMOVAL ..............................................................................................5-22

INSPECTION AND DISASSEMBLY ......................................................5-23

REASSEMBLY AND REMOUNTING ....................................................5-23

REAR SUSPENSION ...................................................................................5-26

CONSTRUCTION ...................................................................................5-26

REMOVAL AND DISASSEMBLY ..........................................................5-27

INSPECTION ..........................................................................................5-28

REASSEMBLY AND REMOUNTING ....................................................5-30

CHASSIS 5-1

5

5-2 CHASSIS

EXTERIOR PARTS

FASTENER REMOVAL AND INSTALLATION

FASTENER

Removal

• Depress the head of fastener center piece 1 .

• Pull out the fastener a .

Installation

• Let the center piece stick out toward the head so that the pawls 2 close.

• Insert the fastener into the installation hole.

NOTE:

To prevent the pawl 2 from damage, insert the fastener all the way into the installation hole.

• Push in the head of center piece until it becomes flush with the fastener outside face.

REMOVAL

SEAT

• Remove the seat 1 .

REAR FENDER AND FRAME COVER

• Remove the rear fender 1 and frame covers 2 .

FUEL TANK COVER

• Remove the fuel tank side cover bolt 1 .

• Remove the fasteners 2 .

• Remove the fuel tank side cover 3 .

• Remove the fuel tank cap 4 .

• Remove the fuel tank upper cover 5 .

NOTE:

Install the fuel tank cap after removing the fuel tank upper cover.

FRONT NUMBER PLATE

• Remove the front number plate 1 .

FRONT FENDER

• Remove the front number plate. ( Above)

• Remove the front fender 1 .

°

: Hook point

FRONT FORK COVER

• Remove the front fork cover 1 .

REASSEMBLY

Reassemble the exterior parts in the reverse order of removal.

CHASSIS 5-3

5-4 CHASSIS

FRONT WHEEL AND FRONT BRAKE

CONSTRUCTION

4

5

6

7

1

2

3

Front axle

Spacer (R)

Dust seal

Bearing (R)

Spacer

Front wheel rim

Bearing (L)

A

B

A

B

8

9

0

Spring

Brake shoe

Brake camshaft

Brake panel

Brake cam lever

Front axle nut

Brake cam lever nut

REMOVAL

• Remove the front fork cover. ( 5-3)

• Remove the front brake adjusting nut 1 .

• Loosen the front brake cable lock-nut 2 .

• Remove the spring 3 , front brake cable 4 and pin 5 .

• Remove the front axle nut 6 .

"

ITEM N·m kgf-m lb-ft

A

B

53

3

5.3

0.3

38.5

2.0

• Support the motorcycle with a jack or wooden block.

Make sure that the motorcycle is securely supported.

• Remove the front axle 7 and spacer 8 .

• Remove the front wheel with the front brake panel.

• Remove the front brake panel 9 .

• Remove the spring 0 and brake shoes A .

• Remove the brake cam lever bolt and nut B .

• Remove the brake cam lever C .

• Remove the washer D , O-ring E and brake camshaft F .

CHASSIS 5-5

5-6 CHASSIS

INSPECTION AND DISASSEMBLY

WHEEL BEARING

Inspect the wheel bearing plays while they are in the wheel.

Rotate the inner race by finger to inspect for abnormal noise and smooth rotation.

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

• Remove the dust seal using the special tool.

\

09913-50121: Oil seal remover

• Insert the adapter 1 into the wheel bearing.

• After inserting the wedge bar 2 from the opposite side, lock the wedge bar into the slit of the adapter.

• Remove the bearing.

\

09941-50111: Bearing remover

FRONT AXLE

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

\

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

09900-20701: Magnetic stand

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

Front axle runout

Service Limit: 0.25 mm (0.010 in)

WHEEL

Make sure that the wheel rim runout (axial and radial) does not exceed the service limit when checked as shown. An excessive amount of runout is usually due to worn or loose wheel bearings and can be corrected by replacing the bearings. If bearing replacement fails to reduce the runout, replace the wheel.

Wheel rim runout

Service Limit (Axial and Radial): 2.0 mm (0.08 in)

SPOKE NIPPLE ( 2-15)

BRAKE DRUM

Inspect the brake drum and measure the brake drum I.D. to determine the extent of wear. Replace the brake drum if the measurement exceeds the service limit. The value of this limit is indicated inside the brake drum.

\

09900-20101: Vernier calipers

Brake drum I.D.

Service Limit: 80.7 mm (3.18 in)

BRAKE SHOES

Inspect the brake shoes wear or damage. If they are worn or damaged, replace them with new ones.

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

REASSEMBLY

Reassemble and install the front wheel in the reverse order of removal and disassembly. Pay attention to the following points:

FRONT WHEEL

• Apply SUZUKI SUPER GREASE “A” to the wheel bearings.

X

99000-25010: SUZUKI SUPER GREASE “A” or equivalent

CHASSIS 5-7

5-8 CHASSIS

• Install the left wheel bearing 1 using the special tool.

• Install the spacer 2 and right wheel bearing 3 using the special tool.

\

09924-84521: Bearing installer set

* The sealed cover of the bearing must face outside.

* The removed bearings must be replaced with new ones.

LH RH LH RH

Removed bearing

• Install the dust seal using the special tool.

\

09913-70210: Bearing installer set

• Apply SUZUKI SUPER GREASE “A” to the dust seal lip.

X

99000-25010: SUZUKI SUPER GREASE “A” or equivalent

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

FRONT BRAKE

• Apply SUZUKI SUPER GREASE “A” to the camshaft.

X

99000-25010: SUZUKI SUPER GREASE “A” or equivalent

Clearance

• Install the O-ring 1 and washer 2 .

The removed O-ring must be replaced with a new one.

• When installing the brake cam lever, align the groove A of the brake camshaft with the slit B on the brake cam lever.

• Tighten the brake cam lever nut to the specified torque.

"

Brake cam lever nut: 3 N·m (0.3 kgf-m, 2.0 lb-ft)

• Apply SUZUKI SUPER GREASE “A” to the brake cam and pin, and install the brake shoes.

X

99000-25010: SUZUKI SUPER GREASE “A” or equivalent

#

Be careful not to apply too much grease to the cam and pin. If grease gets on the lining, brake slippage will result.

REMOUNTING

Remount the front wheel in the reverse order of removal. Pay attention to the following points:

• Align the projection 3 on the left fork leg with the slot 4 on the brake panel.

• Move the front fork up and down 4 or 5 times.

• Tighten the front axle nut to the specified torque.

"

Front axle nut: 53 N·m (5.3 kgf-m, 38.5 lb-ft)

• Adjust the front brake lever play. ( 2-14)

CHASSIS 5-9

5-10 CHASSIS

FRONT FORK

CONSTRUCTION

1

2

Spring joint

Stopper (rubber)

3

4

Front fork spring

Inner tube

REMOVAL

• Remove the front number plate. ( 5-3)

• Remove the front fork cover. ( 5-3)

• Remove the front wheel. ( 5-4)

• Remove the dust seal 1 .

• Remove the snap ring 2 .

• Remove the front fork upper bracket 3 .

• Remove the inner tube 4 with inner parts.

CHASSIS 5-11

5-12 CHASSIS

DISASSEMBLY

• Remove the spring joint 1 , front fork spring 2 and stoppers

3 .

Do not remove the pin 4 .

INSPECTION

FRONT FORK SPRING

Measure the fork spring free length. If it is shorter than the service limit, replace it with a new one.

Front fork spring free length

Service Limit: 154 mm (6.1 in)

STOPPER

Inspect the stopper wear or damage. If defects are found, replace the damper with a new one.

INNER TUBE

Inspect the inner tube sliding surface for any scuffing. If any defects are found, replace the inner tube with a new one.

CHASSIS 5-13

REASSEMBLY AND REMOUNTING

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

Wash the removed parts with cleaning solvent before reassembly.

• Install the front fork spring 1 , stoppers 2 and spring joint 3 .

• Install the front fork spring.

NOTE:

The close-pitch end A of spring must face downward.

• Apply SUZUKI SUPER GREASE “A” (approx. 40 ml) to the inner parts and spring.

X

99000-25010: SUZUKI SUPER GREASE “A” or equivalent

Downward

5-14 CHASSIS

• Align the projection A on the spring joint with the slot B on the outer tube.

• Install the snap ring as shown in the illustration.

After installing the snap ring, always insure that it is completely seated in its groove and securely fitted.

• Tighten the front fork upper bracket bolts 6 to the specified torque.

"

Front fork upper bracket bolt:

45 N·m (4.5 kgf-m, 32.5 lb-ft)

• Install the front wheel and brake. ( 5-9)

• Install the front number plate. ( 5-3)

Inner tube

Snap ring

Outer tube

Rounded part

STEERING

CONSTRUCTION

CHASSIS 5-15

4

5

6

1

2

3

Front fork upper bracket

Steering stem nut

Dust seal

Outer race (upper)

Steering bearing

Inner race (upper)

0

A

B

7

8

9

Inner race (lower)

Outer race (lower)

Front fork outer tube

Handlebars

Front fork upper bracket bolt

Handlebars set bolt

REMOVAL AND DISASSEMBLY

• Remove the front number plate. ( 5-3)

• Remove the front fender. ( 5-3)

• Remove the front wheel and brake. ( 5-4)

"

ITEM N·m kgf-m lb-ft

A 45 4.5

32.5

B 23 2.3

16.5

5-16 CHASSIS

• Remove the starter cable 1 .

• Remove the throttle case 2 and throttle grip 3 .

• Remove the handlebars 4 .

• Remove the front fork upper bracket 5 .

• Remove the steering stem nut 6 using the special tool.

\

09940-14911: Steering nut socket wrench

NOTE:

Hold the front fork by hand to prevent falling.

• Remove the dust seal 7 .

• Remove the outer racer 8 .

• Remove the upper and lower bearings 9 .

INSPECTION

Inspect the removed parts for the following abnormalities.

* Handlebars distortion

* Race wear and brinelling

* Bearing wear or damage

* Distortion of the steering stem

If any abnormal condition are found, replace defective parts with new ones.

• Remove the lower outer race using a chisel.

The removed outer race must be replaced with a new one.

• Drive out the upper and lower inner races using a suitable bar.

The removed inner race must be replaced with a new one.

CHASSIS 5-17

5-18 CHASSIS

REASSEMBLY AND REMOUNTING

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

INNER RACE

• Press in the upper and lower inner races using the special tool.

\

09941-34513: Steering race installer

OUTER RACE

• Install the lower outer race using the special tool.

\

09940-51410: Steering bearing installer

09913-70210: Bearing installer set

BEARING

• Apply SUZUKI SUPER GREASE “A” to the upper and lower bearings.

X

99000-25010: SUZUKI SUPER GREASE “A” or equivalent

STEERING STEM

• Tighten the steering stem nut 1 at 45 N·m (4.5 kgf-m, 32.5 lb-ft).

• Turn the steering stem five or six times to the left and right.

• Loosen the steering stem nut 1/8 – 1/4 of a turn A .

\

09940-14911: Steering nut socket wrench

NOTE:

This adjustment will vary from motorcycle to motorcycle. Make sure that the steering stem turns smoothly and easily in both directions.

• Install the front fork upper bracket.

• Tighten the front fork upper bolts to the specified torque.

"

Front fork upper bracket bolt:

45 N·m (4.5 kgf-m, 32.5 lb-ft)

• Tighten the handlebars set bolts to the specified torque.

"

Handlebars set bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

HANDLEBAR RIGHT SIDE PARTS

• Install the throttle cable.

• Apply SUZUKI SUPER GREASE “A” to the throttle cable end.

X

99000-25010: SUZUKI SUPER GREASE “A” or equivalent

• When installing the throttle case, align the throttle cable holder edge B with the throttle case C .

• Align the projection D of the throttle case with the hole E on the handlebars.

NOTE:

Tighten the upper screw first and then lower screw to screw the throttle case.

CHASSIS 5-19

5-20 CHASSIS

HANDLEBAR LEFT SIDE PARTS

• Apply handle grip bond onto the handlebars before installing the handlebar left grip.

Handle grip bond

Handlebars

• When installing the left handlebar grip, align the “ U ” mark F with the punched mark G on handlebars.

• Install the front wheel and brake. ( 5-9)

• Install the front fender. ( 5-3)

• Install the front number plate. ( 5-3)

NOTE:

Hold the front fork legs, move them back and forth and make sure that the steering is not loose.

After performing the adjustment and installing the handlebars, “rock” the front wheel assembly forward and backward to ensure that there is no play and that the procedure was accomplished correctly. Finally, check to make sure that the steering stem moves freely from left to right with its own weight. If play or stiffness is noticeable, re-adjust the steering stem nut.

REAR WHEEL AND REAR BRAKE

CONSTRUCTION

CHASSIS 5-21

5

6

7

8

9

1

2

3

4

Chain adjuster

Rear axle spacer

Rear sprocket

Dust seal

Bearing

Spacer

Rear wheel rim

Rear brake rod

Spring

D

A

B

C

0

A

B

C

Brake shoe

Brake camshaft

Brake panel

Brake cam lever

Rear axle

Rear axle nut

Rear sprocket bolt

Rear brake cam lever nut

"

ITEM N·m kgf-m lb-ft

A

B

C

54

27

3

5.4

2.7

0.3

39.0

19.5

2.0

5-22 CHASSIS

REMOVAL

• Remove the rear brake adjusting nut 1 .

• Loosen the lock-nuts and chain adjusters 2 right and left.

• Support the motorcycle with a jack or wooden block.

• Remove the rear axle nut 3 and rear axle 4 .

• Disengage the drive chain 5 from the rear sprocket.

• Remove the rear wheel with the rear brake panel.

• Remove the rear brake panel 6 .

• Remove the rear axle spacer 7 .

• Remove the rear sprocket 8 by removing the mounting nuts and bolts.

• Remove the dust seal 9 using special tool.

\

09913-50121: Oil seal remover

REAR BRAKE ( 5-5)

INSPECTION AND DISASSEMBLY

WHEEL BEARINGS ................................................. 5-6

AXLE ........................................................................ 5-6

WHEEL .................................................................... 5-6

SPOKE NIPPLES..................................................... 2-15

BRAKE DRUM ......................................................... 5-7

BRAKE SHOES ....................................................... 5-7

REAR SPROCKET

Inspect the rear sprocket teeth for wear. If they are worn, replace the sprocket and drive chain.

A Normal wear

B Excessive wear

REASSEMBLY AND REMOUNTING

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

REAR WHEEL

• Apply SUZUKI SUPER GREASE “A” to the wheel bearings.

X

99000-25010: SUZUKI SUPER GREASE “A” or equivalent

CHASSIS 5-23

5-24 CHASSIS

• Install the right wheel bearings 1 using the special tool.

• Install the spacer 2 and left wheel bearings 3 using the special tool.

\

09924-84521: Bearing installer set

* The sealed cover of the bearing must face outside.

* The removed bearings must be replaced with new ones.

LH RH LH RH

Clearance

• Install the dust seal using the special tool.

\

09913-70210: Bearing installer set

• Apply SUZUKI SUPER GREASE “A” to the dust seal lip.

X

99000-25010: SUZUKI SUPER GREASE “A” or equivalent

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

• Install the rear sprocket and tighten the bolts to the specified torque.

"

Rear sprocket bolt: 27 N·m (2.7 kgf-m, 19.5 lb-ft)

NOTE:

The stamped mark A on the rear sprocket should face to the outside.

Removed bearing

(

REAR BRAKE

5-8 and 5-9)

• Align the boss 1 on the swingarm with the slot 2 on the brake panel.

• Tighten the rear axle nut to the specified torque.

"

Rear axle nut: 54 N·m (5.4 kgf-m, 39.0 lb-ft)

• Adjust the drive chain slack after installing the rear wheel.

( 2-13)

• Adjust the rear brake pedal free travel. ( 2-14)

CHASSIS 5-25

5-26 CHASSIS

REAR SUSPENSION

CONSTRUCTION

1

2

3

4

Rear shock absorber

Swingarm pivot shaft

Bushing

Swingarm

5

A

B

Chain buffer

Swingarm pivot nut

Rear shock absorber mounting nut

"

ITEM N·m kgf-m lb-ft

A 42 4.2

30.5

B 50 5.0

36.0

REMOVAL AND DISASSEMBLY

REAR SHOCK ABSORBER

• Support the motorcycle with a jack or wooden block.

• Remove the seat. ( 5-3)

• Remove the rear shock absorber mounting nut (upper and lower).

• Remove the rear shock absorber 1 .

• Remove the spacers 2 and bushings 3 .

SWINGARM

• Remove the engine sprocket cover 1 .

• Remove the rear wheel and brake. ( 5-22)

• Remove the drive chain 2 .

• Remove the swingarm pivot nut 3 .

• Remove the swingarm pivot shaft 4 and swingarm 5 .

CHASSIS 5-27

5-28 CHASSIS

• Remove the chain cover 6 .

• Remove the chain guide 7 .

• Remove the chain buffer 8 .

INSPECTION

REAR SHOCK ABSORBER

Inspect the rear shock absorber for oil leakage or other damage.

If any oil leakage or damages are found, replace the rear shock absorber with a new one.

Do not attempt to disassemble the rear shock absorber. It is unserviceable.

CHAIN BUFFER

Inspect the chain buffer for damage. If any defects are found, replace the chain buffer with a new one.

SWINGARM BUSHING

Inspect the swingarm bushing for damage.

If any defects are found, replace the swingarm bushing with a new one.

• Using appropriate steel tube 1 and vise, remove the bushing

2 .

CHASSIS 5-29

• Using an appropriate size steel tubes and vise, install the swingarm bushing.

NOTE:

Align the surface A of bushing 3 with swingarm inner surface

4 .

SWINGARM

Inspect the swingarm for damage.

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

5-30 CHASSIS

SWINGARM PIVOT SHAFT

Measure the swingarm pivot shaft runout using the dial gauge. If the pivot shaft exceeds the service limit, replace it with a new one.

\

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

09900-20701: Magnetic stand

09900-21304: V-block (100 mm)

Swingarm pivot shaft runout

Service Limit: 0.6 mm (0.02 in)

REASSEMBLY AND REMOUNTING

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

• Install the swingarm.

• Tighten the swingarm pivot nut to the specified torque.

"

Swingarm pivot nut: 42 N·m (4.2 kgf-m, 30.5 lb-ft)

• Tighten the rear shock absorber mounting nuts to the specified torque.

"

Rear shock absorber mounting nut:

50 N·m (5.0 kgf-m, 36.0 lb-ft)

After installing the rear suspension and wheel adjust the following.

* Drive chain slack ................................................... 2-13

* Rear brake pedal free travel ................................. 2-14

ELECTRICAL SYSTEM

ELECTRICAL SYSTEM 6-1

CONTENTS

CAUTIONS IN SERVICING ...........................................................................6- 2

CONNECTOR..........................................................................................6- 2

COUPLER ...............................................................................................6- 2

CLAMP ....................................................................................................6- 2

FUSE .......................................................................................................6- 2

SEMI-CONDUCTOR EQUIPPED PART .................................................6- 3

BATTERY ................................................................................................6- 3

WIRING PROCEDURE............................................................................6- 3

USING THE MULTI-CIRCUIT TESTER ..................................................6- 3

LOCATION OF ELECTRICAL COMPONENTS ............................................6- 4

CHARGING SYSTEM ....................................................................................6- 5

TROUBLESHOOTING ............................................................................6- 5

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

STARTER SYSTEM.......................................................................................6- 9

TROUBLESHOOTING ............................................................................6- 9

STARTER MOTOR REMOVAL...............................................................6-10

STARTER MOTOR DISASSEMBLY.......................................................6-11

STARTER MOTOR INSPECTION...........................................................6-12

STARTER MOTOR REASSEMBLY AND INSTALLATION ...................6-13

STARTER RELAY INSPECTION............................................................6-15

IGNITION SYSTEM........................................................................................6-16

TROUBLESHOOTING ............................................................................6-16

INSPECTION ...........................................................................................6-18

SWITCHES ....................................................................................................6-20

BATTERY ......................................................................................................6-21

SPECIFICATIONS...................................................................................6-21

INITIAL CHARGING................................................................................6-21

SERVICING .............................................................................................6-22

RECHARGING OPERATION ..................................................................6-23

6

6-2 ELECTRICAL SYSTEM

CAUTIONS IN SERVICING

CONNECTOR

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

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

Click

COUPLER

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

• When disconnecting the coupler, be sure to hold the coupler itself and do not pull the lead wires.

• Inspect each terminal on the coupler for being looseness or bending.

• Inspect each terminal for corrosion and contamination.

• Push in the coupler straightly. An angled or skewed insertion may cause the terminal to be deformed, possibly resulting in poor electrical contact.

• Before refitting the sealed coupler, make sure seal rubber is positioned properly. The seal rubber may possibly come off the position during disconnecting work and if the coupler is refitted with the seal rubber improperly positioned, it may result in poor water sealing.

CLAMP

• Clamp the wire harness at such positions as indicated in

“WIRING HARNESS ROUTING”. ( 7-11)

• Bend the clamp properly so that the wire harness is clamped securely.

• In clamping the wire harness, use care not to allow it to hang down.

• Do not use wire or any other substitute for the band type clamp.

FUSE

• When a fuse blows, always investigate the cause to correct it and then replace the fuse.

• Do not use a fuse of a different capacity.

• Do not use wire or any other substitute for the fuse.

Click

CORRECT INCORRECT

SEMI-CONDUCTOR EQUIPPED PART

• Be careful not to drop the part which has a semi-conductor built in such as a CDI unit and regulator/rectifier.

• When inspecting these parts, follow the instructions carefully.

Failure to follow the proper procedure can cause damage to these parts.

INCORRECT

ELECTRICAL SYSTEM 6-3

BATTERY

• The MF battery used in this motorcycle 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.

WIRING PROCEDURE

• Properly route the wire harness according to the “WIRING

HARNESS ROUTING” section. ( 7-11)

USING THE MULTI-CIRCUIT TESTER

• Properly use the multi-circuit tester + and probes.

Improper use can cause damage to the motorcycle and tester.

• If the voltage and current values are not known, begin measuring in the highest range.

• When measuring the resistance, make sure that no voltage is applied. If voltage is applied, the tester will be damaged.

• After using the tester, be sure to turn the switch to the OFF position.

\

09900-25008: Multi-circuit tester set

Before using the multi-circuit tester, read its instruction manual.

6-4 ELECTRICAL SYSTEM

LOCATION OF ELECTRICAL COMPONENTS

Regulator/rectifier

Generator

Fuse (10 A)

Battery

Starter relay

CDI unit

Starter motor

Ignition coil

Ignition switch

Starter button

Engine stop switch

ELECTRICAL SYSTEM 6-5

CHARGING SYSTEM

B/R

B/R

Generator

Regulator/ rectifier

B/W

R

B/W

Fuse

10A

B

Battery

TROUBLESHOOTING

NOTE:

* Make sure that the fuse is not blown and the battery is fully-charged before diagnosing.

Battery runs down quickly.

Step 1

1) Check accessories which use excessive amounts of electricity.

Are accessories installed?

YES

NO

Remove accessories.

Go to Step 2.

Step 2

1) Measure the regulated voltage between the battery terminals. ( 6-6)

Is the regulated voltage OK?

YES

NO

• Faulty battery.

• Abnormal driving condition.

Go to Step 3.

Step 3

1) Measure the resistance of the generator coil. ( 6-7)

Is the resistance of generator coil OK?

YES

NO

Go to Step 4.

• Faulty generator coil.

• Disconnected lead wires.

Step 4

1) Measure the generator no-load performance. ( 6-7)

Is the generator no-load performance OK?

YES

NO

Go to Step 5.

Faulty generator.

6-6 ELECTRICAL SYSTEM

Step 5

1) Inspect the regulator/Rectifier. ( 6-8)

Is the regulator/rectifier OK?

YES

NO

Go to Step 6.

Faulty regulator/rectifier.

Step 6

1) Inspect wire harness.

Is the wire harness OK?

YES

NO

Faulty battery.

• Short circuit of wire harness.

• Poor contact of couplers.

Battery overcharges.

• Faulty regulator/rectifier.

• Faulty battery.

• Poor contact of generator lead wire coupler.

INSPECTION

REGULATED VOLTAGE

• Remove the seat. ( 5-2)

• Remove the battery cover 1 .

• Start the engine and keep it running at 5 000 r/min.

Measure the DC voltage between the + and battery terminals using the multi-circuit tester. If the voltage is not within the specified value, inspect the generator and regulator/rectifier.

( 6-7 and -8)

NOTE:

When making this test, be sure that the battery is in fully-charged condition.

\

09900-25008: Multi-circuit tester set

W

Tester knob indication: Voltage ( )

Regulated voltage (Charging output):

13.5 – 15.2 V at 5 000 r/min

Battery

DCV

ELECTRICAL SYSTEM 6-7

GENERATOR COIL RESISTANCE

• Disconnect the generator coupler 1 .

Measure the resistance between the B/R lead wire and ground using the multi-circuit tester. If the resistance is not within the specified value, replace the generator coil with a new one.

\

09900-25008: Multi-circuit tester set

V

Tester knob indication: Resistance ( Ω )

Generator coil resistance:

0.6 – 2.0 Ω (Black/Red – Ground)

B/R

GENERATOR NO-LOAD PERFORMANCE

• Disconnect the regulator/rectifier coupler 1 .

• Start the engine and keep it running at 5 000 r/min.

Measure the voltage between the B/R wire of regulator/rectifier coupler and ground using the multi-circuit tester.

If the tester reads under the specified value, replace the generator with a new one.

\

09900-25008: Multi-circuit tester set

W

Tester knob indication: Voltage (~)

Generator no-load performance

30 V (AC) and more at 5 000 r/min (When engine is cold)

B/R

V

6-8 ELECTRICAL SYSTEM

REGULATOR/RECTIFIER

• Disconnect the regulator/rectifier coupler 1 .

• Remove the regulator/rectifier 2 .

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

+ Tester probe

A

A B

±

C

±

B

C

±

±

0.9 – 1.4

1.3 – 1.6

±

1.4 V and more (tester’s battery voltage)

NOTE:

If the tester reads 1.4 V and below when the tester probes are not connected, replace its battery.

ELECTRICAL SYSTEM 6-9

STARTER SYSTEM

Starter relay

Starter motor

R

Bl

Bl

Neutral switch

Y/G

CDI unit O/W

Y/G O/W

B/W

Starter button

Engine stop switch

O

O O

Ignition switch

R

R

10A

Battery

R

B

TROUBLESHOOTING

NOTE:

* Make sure that the fuse is not blown and the battery is fully-charged before diagnosing.

Starter motor will not run.

Step 1

1) Check that the transmission is in neutral and the engine stop switch is in the “RUN” position.

2) Turn the ignition switch to the “ON” position.

3) Listen for a click sound from the starter relay when the starter button is pushed.

Is a click sound heard?

YES

NO

Go to Step 2.

Go to Step 3.

Step 2

1) Check if the starter motor runs when its terminal is connected to the battery + terminal. (Do not use thin

“wire” because a large amount of current flows.)

Does the starter motor run?

YES

NO

• Faulty starter relay.

• Loose or disconnected starter motor lead wire.

• Loose or disconnected between starter relay and battery + terminal.

Faulty starter motor.

Step 3

1) Measure the starter relay voltage at the starter relay coupler (between Y/G + and Bl ) when the starter button is pushed.

Is the voltage OK?

YES

NO

Go to Step 4.

• Faulty starter button.

• Faulty engine stop switch.

• Faulty ignition switch.

• Poor contact of couplers.

• Open circuit of wire harness.

6-10 ELECTRICAL SYSTEM

Step 4

1) Check the starter relay. ( 6-15)

Is the starter relay OK?

YES

NO

Poor contact of the starter relay.

Faulty starter relay.

Starter motor runs but does not crank the engine.

Check the starter clutch. ( 3-45)

STARTER MOTOR REMOVAL

• Remove the exhaust pipe cover 1 .

• Disconnect the starter motor coupler 2 .

• Remove the starter motor 3 and ground wire 4 .

STARTER MOTOR DISASSEMBLY

ELECTRICAL SYSTEM 6-11

1

4

O-ring

Starter motor case

• Remove the O-ring 1 .

2 Housing end 3 Armature

• Remove the housing end 2 .

6-12 ELECTRICAL SYSTEM

• Remove the O-ring 3 .

• Remove the armature 4 .

STARTER MOTOR INSPECTION

CARBON BRUSH

Inspect the brushes for abnormal wear, cracks, or smoothness in the brush holder.

If any defects are found, replace the housing end assembly with a new one.

Make sure that the length A is not less than 3.5 mm (0.14 in), If this length becomes less than 3.5 mm (0.14 in), replace the housing end assembly.

Starter motor brush length

Service Limit: 3.5 mm (0.14 in)

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 sand paper and wipe it using a clean dry cloth.

If there is no undercut, scrape out the insulator with a saw blade.

1 Insulator

2 Segment

ARMATURE COIL

Check for continuity 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 oil seal lip for damage or leakage.

If any defects are found, replace the housing end assembly.

BUSH

Check the bush for wear and damage.

If any defects are found, replace the starter motor case.

STARTER MOTOR REASSEMBLY AND

INSTALLATION

Reassemble and installation the starter motor in the reverse order of disassembly. Pay attention to the following points:

• Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal and bearing.

X

99000-25010: SUZUKI SUPER GREASE “A” or equivalent

• Apply a small quantity of SUZUKI MOLY PASTE to the armature shaft.

Z

99000-25140: SUZUKI MOLY PASTE or equivalent

ELECTRICAL SYSTEM 6-13

6-14 ELECTRICAL SYSTEM

• Install the O-ring 1 .

The removed O-ring must be replaced with a new one.

• Fit the projection A of the starter motor case 2 to the depression B of the housing end 3 .

• Install the O-rings 3 .

The removed O-rings must be replaced with new ones.

• Install the O-ring 4 .

The removed O-ring must be replaced with a new one.

• Apply SUZUKI SUPER GREASE “A” to the O-ring.

X

99000-25010: SUZUKI SUPER GREASE “A” or equivalent

• Install the starter motor and ground wire 5 .

• Tighten the starter motor mounting bolts 6 to the specified torque.

"

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

STARTER RELAY INSPECTION

• Remove the seat. ( 5-2)

• Remove the starter relay 1 .

• First check the insulation between C and D terminals with the multi-circuit tester.

• Then apply 12 V to A and B terminals and check for continuity between the C and D terminals. If the starter relay clicks and continuity are found, the relay is OK.

\

09900-25008: Multi-circuit tester set

=

Tester knob indication: Continuity test (

?

)

Do not apply battery voltage to the starter relay for more than five seconds, since the relay coil may overheat and get damaged.

Measure the relay coil resistance between the A and B terminals using the multi-circuit tester. If the resistance is not within the specified value, replace the starter relay with a new one.

\

09900-25008: Multi-circuit tester set

V

Tester knob indication: Resistance (

Ω

)

Starter relay resistance: 70 – 90

Ω

ELECTRICAL SYSTEM 6-15

6-16 ELECTRICAL SYSTEM

IGNITION SYSTEM

O

O/W

Y/G CDI unit

Bl

R O O O/W Y/G

Fuse

10A

R

Ignition switch

R

Engine stop switch

Starter button

Regulator/ rectifier

B/R

B/W

R

Battery

B

Generator

B/Bl B/W

Neutral switch

B/Bl

B/Y

B/W

Ignition coil

Spark plug

TROUBLESHOOTING

NOTE:

* Make sure the fuse is not blown and the battery is fully-charged before diagnosing.

* Make sure the transmission is in neutral and the engine stop switch is in the “RUN” position.

No spark or poor spark

Step 1

1) Check the ignition system couplers for poor connections.

Are there connection in the ignition system couplers?

YES

NO

Go to Step 2.

Poor connection of couplers.

Step 2

1) Measure the battery voltage between input lead wires (O/W and B/W) at the CDI unit with the ignition switch in the “ON” position.

Is the voltage OK?

YES

NO

Go to Step 3.

• Faulty ignition switch.

• Faulty wire harness.

• Faulty engine stop switch.

• Poor connection of related circuit couplers.

ELECTRICAL SYSTEM 6-17

Step 3

1) Measure the ignition coil primary peak voltage. ( 6-18)

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. ( 2-8)

Is the spark plug OK?

YES

NO

• Go to Step 5.

Faulty spark plug.

Step 5

1) Inspect the ignition coil. ( 6-18 and -19)

Is the ignition coil OK?

YES

NO

Go to Step 6.

• Poor connection of the ignition coil.

• Faulty ignition coil.

Step 6

1) Measure the pick-up coil peak voltage and pick-up coil resistance. ( 6-19 and -20)

NOTE:

The pick-up coil peak voltage inspection is applicable only with the multi-circuit tester and peak volt adaptor.

Is the peak voltage and resistance OK?

YES

NO

• Faulty CDI unit.

• Open or short circuit of wire harness.

• Poor connection of generator coupler.

• Faulty pick-up coil.

• Metal particles or foreign material being stuck on the pick-up coil and motor tip.

6-18 ELECTRICAL SYSTEM

INSPECTION

IGNITION COIL PRIMARY PEAK VOLTAGE

• Remove the spark plug cap 1 .

• Connect a new spark plug 2 to the spark plug cap and ground it on the cylinder head.

NOTE:

Make sure that the spark plug cap and spark plug are connected properly.

Measure the ignition coil primary peak voltage using the multi-circuit tester in the following procedure.

• Connect the multi-circuit tester with the peak volt adaptor as follows.

+ Probe: Black/White lead wire

Probe: Black/Yellow lead wire

NOTE:

Do not disconnect the ignition coil lead wires.

\

09900-25008: Multi-circuit tester set

Before using the multi-circuit tester and peak volt adaptor, be sure to refer to the appropriate instruction manual.

CDI unit

• Turn the ignition switch to the “ON” position.

• Push the starter button and allow the engine to crank for a few seconds, and then measure the ignition coil primary peak voltage.

• Repeat the above procedure a few times and measure the highest ignition coil primary peak voltage.

W

Tester knob indication: Voltage ( )

Ignition coil primary peak voltage: 150 V and more

#

While testing, do not touch the tester probes and spark plug to prevent receiving an electric shock.

If the voltage is lower than the specified values, inspect the ignition coil. ( 6-19)

B / Y

B / W

New spark plug

Peak volt adaptor

ELECTRICAL SYSTEM 6-19

IGNITION COIL RESISTANCE

• Remove the spark plug cap. ( 6-18)

• Disconnect the ignition coil lead wires 1 , 2 and remove the ignition coil 3 .

Measure the ignition coil resistance in both the primary and secondary windings using the multi-circuit tester. If the resistance is not within the specified value, replace the ignition coil.

\

09900-25008: Multi-circuit tester set

V

Tester knob indication: Resistance (

Ω

)

Ignition coil resistance

Primary: 0.1 – 0.8 Ω ( + Terminal – Terminal)

Secondary: 13 – 20 k

Ω

(Plug cap – Terminal)

PICK-UP COIL PEAK VOLTAGE

NOTE:

Make sure that all of the couplers are connected properly and the battery is fully charged.

• Disconnect the generator coupler 1 .

Measure the pick-up coil peak voltage in the following procedure.

• Connect the multi-circuit tester with the peak volt adaptor as follows.

+ Probe: Black/Blue lead wire

Probe: Ground

\

09900-25008: Multi-circuit tester set

Before using the multi-circuit tester and peak volt adaptor, be sure to refer to the appropriate instruction manual.

• Turn the ignition switch to the “ON” position.

• Push the starter button and allow the engine for a few seconds, and then measure the pick-up coil peak voltage.

• Repeat the above procedure a few times and measure the highest pick-up coil peak voltage.

W

Tester knob indication: Voltage ( )

Pick-up coil peak voltage: 1.2 V and more

If the peak voltage is within specification, check the continuity between the pick-up coil coupler and CDI unit coupler.

Generator generator coupler

B/Bl

Peak volt adaptor

6-20 ELECTRICAL SYSTEM

PICK-UP COIL RESISTANCE

Measure the resistance between the lead wire and ground using the multi-circuit tester. If the resistance is not within the specified value, the pick-up coil must be replaced.

\

09900-25008: Multi-circuit tester set

V

Tester knob indication: Resistance ( Ω )

Pick-up coil resistance:

150 – 240 Ω (When engine is cold)

Generator generator coupler

B/Bl

SWITCHES

Measure each switch for continuity using the multi-circuit tester. If there is no continuity, replace the respective switch with a new one.

IGNITION SWITCH

Color

Position

OFF

ON

R

STARTER BUTTON

Color

Position

O/W

PUSH

O

Y/G

NEUTRAL SWITCH

Color

Position

ON

OFF

Bl

ENGINE STOP SWITCH

Color

Position

OFF ( )

RUN ( )

O

WIRE COLOR

Bl : Blue

O : Orange

R : Red

O/W : Orange with White tracer

Y/G : Yellow with Green tracer

Graund

O/W

BATTERY

SPECIFICATIONS

Type designation

Capacity

YT4B-BS

12 V, 8.28 kC (2.3 Ah)/10 HR

INITIAL CHARGING

Filling electrolyte

• Remove the aluminum tape 1 sealing the battery electrolyte filler holes.

NOTE:

When filling electrolyte, the battery must be removed from the motorcycle and must be put on the level ground.

• Remove the caps 2 .

NOTE:

* After filling the electrolyte completely, use the removed caps

2 as the sealed caps of battery-filler holes.

* Do not remove or pierce the sealed areas 3 of the electrolyte container.

• Insert the nozzles of the electrolyte container 4 into the battery’s electrolyte filler holes, holding the container firmly so that it does not fall. Take precaution not to allow any of the fluid to spill.

• Make sure air bubbles 5 are coming up each electrolyte container, and leave in this position for about more than 20 minutes.

ELECTRICAL SYSTEM 6-21

6-22 ELECTRICAL SYSTEM

NOTE:

If no air bubbles are coming up from a filler port, tap the bottom of the two or three times.

Never remove the container from the battery.

• After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the battery. Wait for around 20 minutes.

• Insert the caps into the filler holes, pressing in firmly so that the top of the caps do not protrude above the upper surface of the battery’s top cover.

* Never use anything except the specified battery.

* Once the caps have been installed to the battery, do not remove the caps.

* Do not tap the caps with a tool such as hammer when installing them.

CORRECT

For initial charging, use the charger specially designed for MF battery.

INCORRECT

* For charging the battery, make sure to use the charger specially designed for MF battery. Otherwise, the battery may be overcharged resulting in shortened service life.

* Do not remove the cap during charging.

* Position the battery with the cap facing upward during charging.

SERVICING

Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, then this can be cleaned away with sandpaper.

ELECTRICAL SYSTEM 6-23

RECHARGING OPERATION

• Using the multi-circuit tester, check the battery voltage. If the voltage reading is 12.0 V (DC) or less, recharge the battery with a battery charger.

A Charging period

B Stop charging

* When recharging the battery, remove the battery from the motorcycle.

* Do not remove the caps on the battery top while recharging.

Recharging time: 0.3 A for 8 to 10 hours or 3 A for 0.5 hour

Be careful not to permit the charging current to exceed 3 A at any time.

• After recharging, wait for 30 minutes or more and check the battery voltage with a multi-circuit tester.

• If the battery voltage is 12.5 V or less, recharge the battery again.

• If battery voltage is still 12.5 V or less, after recharging, replace the battery with a new one.

• When the motorcycle is not used for a long period, check the battery every 1 month to prevent the battery discharge.

12

11

10

(V)

14

13

(at 0 – 40 ˚C)

100 75 50 25

Battety charged condition

0 (%)

7-1 SERVICING INFORMATION

SERVICING INFORMATION

CONTENTS

TROUBLESHOOTING ...................................................................................7- 2

ENGINE ...................................................................................................7- 2

CLUTCH ..................................................................................................7- 5

CARBURETOR .......................................................................................7- 5

CHASSIS .................................................................................................7- 6

BRAKES..................................................................................................7- 7

ELECTRICAL ..........................................................................................7- 8

BATTERY ................................................................................................7- 9

WIRING DIAGRAM .................................................................................7-10

WIRING HARNESS, CABLE AND HOSE ROUTING....................................7-11

WIRING HARNESS ROUTING ...............................................................7-11

CABLE ROUTING ...................................................................................7-13

CARBURETOR HOSE ROUTING...........................................................7-14

FUEL HOSE AND FUEL TANK BREATHER HOSE ROUTING ............7-15

HANDLEBAR INSTALLATION .....................................................................7-16

SIDE-STAND INSTALLATION ......................................................................7-17

REAR BRAKE PEDAL INSTALLATION .......................................................7-17

FUEL TANK UPPER COVER CUSHION INSTALLATION ...........................7-18

FUEL TANK SIDE COVER CUSHION INSTALLATION ...............................7-18

SPECIAL TOOLS ..........................................................................................7-19

TIGHTENING TORQUE .................................................................................7-21

ENGINE ...................................................................................................7-21

CHASSIS .................................................................................................7-22

TIGHTENING TORQUE CHART.............................................................7-22

SERVICE DATA.............................................................................................7-23

SERVICING INFORMATION 7-2

TROUBLESHOOTING

ENGINE

Complaint

Engine will not start, or is hard to start.

Symptom and possible causes

Compression too low

1. Valve clearance out of adjustment.

2. Worn valve guides or poor seating of valves.

3. Mistiming valves.

4. Excessively worn piston rings.

5. Worn-down cylinder bore.

6. Too slowly starter motor cranks.

7. Poor seating of spark plug.

8. Gas leaks from the joint in crankcase, cylinder or cylinder head.

Remedy

Adjust.

Repair or replace.

Adjust.

Replace.

Replace or rebore.

See electrical section.

Retighten.

Repair or replace.

Plugs not sparking

1. Fouled spark plug.

2. Wet spark plug.

3. Defective ignition coil.

4. Open or short in high-tension cord.

5. Defective pick-up coil or CDI unit.

6. Open or short circuited wiring connections.

Engine stalls often.

Noisy engine.

No fuel reaching the carburetors

1. Clogged hole in the fuel tank cap.

2. Defective carburetor needle valve.

3. Clogged fuel hose or fuel filter.

1. Fouled spark plug.

2. Defective pick-up coil or CDI unit.

3. Clogged fuel hose or fuel tank cap.

4. Clogged jets in carburetor.

5. Valve clearance out of adjustment.

6. Clogged exhaust pipe.

7. Open or short circuited wiring connection.

Excessive valve chatter

1. Too large valve clearance.

2. Weakened or broken valve springs.

3. Worn rocker arm or cam surface.

4. Worn or burnt camshaft bearings.

Noise seems to come from piston

1. Worn down piston or cylinder.

2. Combustion chamber fouled with carbon.

3. Worn piston pin or piston pin bore.

4. Worn piston rings or ring grooves.

Clean.

Clean and dry.

Replace.

Replace.

Replace.

Repair or replace.

Clean or replace.

Replace.

Clean or replace.

Clean.

Replace.

Clean or replace.

Clean.

Adjust.

Clean.

Repair or replace.

Adjust.

Replace.

Replace.

Replace.

Replace.

Clean.

Replace.

Replace.

7

7-3 SERVICING INFORMATION

Complaint

Noisy engine.

Symptom and possible causes

Noise seems to come from timing chain

1. Stretched chain.

2. Worn sprocket.

3. Not working tension adjuster.

Remedy

Replace.

Replace.

Repair or replace.

Noise seems to come from clutch

1. Worn splines of countershaft or hub.

2. Worn teeth of clutch plates.

3. Distorted clutch plates, driven and drive.

Noise seems to come from crankshaft

1. Worn or rattling bearings.

2. Worn or burnt big-end bearing.

3. Worn or burnt journal bearings.

4. Too large thrust clearance.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Engine idles poorly.

Transmission will not shift.

Transmission jumps out of gear.

Noise seems to come from transmission

1. Worn or rubbing gears.

2. Worn splines.

3. Worn or rubbing primary gears.

4. Worn bearings.

1. Valve clearance out of adjustment.

2. Poor seating of valves.

3. Defective valve guides.

4. Worn down camshaft.

5. Too wide spark plug gap.

6. Defective ignition coil.

7. Defective CDI unit.

8. Defective generator coil.

9. Clogged carburetor jet.

10. Idle adjust screw and air screw out of adjustment

11. Damaged or cracked vacuum hose.

12. Clogged air cleaner element.

13. Incorrect float chamber fuel level.

Replace.

Replace.

Replace.

Replace.

Adjust.

Repair or replace.

Replace.

Replace.

Adjust or replace.

Replace.

Replace.

Replace.

Clean or replace.

Adjust.

1. Broken gearshift cam.

2. Distorted gearshift forks.

3. Worn gearshift pawl.

4. Clutch release screw out of adjustment.

1. Worn shifting gears on driveshaft or countershaft.

2. Distorted or worn gearshift forks.

3. Weakened stopper spring on gearshift stopper.

4. Worn gearshift cam plate.

Replace.

Clean or replace.

Adjust float height.

Replace.

Replace.

Replace.

Adjust.

Replace.

Replace.

Replace.

Replace.

SERVICING INFORMATION 7-4

Complaint

Engine runs poorly in high speed range.

Dirty or heavy exhaust smoke.

Symptom and possible causes

1. Weakened valve spring.

2. Worn camshaft.

3. Valve timing out of adjustment.

4. Too narrow spark plug gap.

5. Ignition not advanced sufficiently due to poorly working timing advance circuit.

6. Defective ignition coil.

7. Defective pick-up coil or CDI unit.

8. Too low float-chamber fuel level.

9. Clogged air cleaner element.

10. Clogged fuel hose, resulting in inadequate fuel supply to carburetor.

1. Too much engine oil in the engine.

Engine lacks power.

Engine overheats

2. Worn piston rings or cylinder.

3. Worn valve guides.

4. Scored or scuffed cylinder wall.

5. Worn valves or stems.

6. Defective stem seals.

7. Worn oil ring side rails.

1. Loss of valve clearance.

2. Weakened valve spring.

3. Valve timing out of adjustment.

4. Worn piston rings or cylinder.

5. Poor seating of valves.

6. Fouled spark plug.

7. Incorrect spark plug.

8. Clogged jets in carburetor.

9. Float-chamber fuel level out of adjustment.

10. Clogged air cleaner element.

11. Sucking air from intake pipe.

12. Too much engine oil.

13. Defective CDI unit.

1. Heavy carbon deposit on piston crown.

2. Not enough oil in the engine.

3. Defective oil pump or clogged oil circuit.

4. Too low in float chambers fuel level.

5. Sucking air from intake pipe.

6. Use of incorrect engine oil.

7. Clogged air intake with dust.

Remedy

Replace.

Replace.

Adjust.

Adjust.

Replace CDI unit.

Replace.

Replace.

Adjust.

Clean.

Clean and prime.

Check oil level and drain out excess.

Replace.

Replace.

Rebore or replace.

Replace.

Replace.

Replace.

Adjust.

Replace.

Adjust.

Replace.

Repair.

Clean or replace.

Adjust or replace.

Clean.

Adjust.

Clean.

Retighten or replace.

Drain out excess oil.

Replace.

Clean.

Add oil.

Replace or clean.

Adjust.

Retighten or replace.

Change.

Clean.

7-5 SERVICING INFORMATION

CLUTCH

Slipping clutch.

Dragging clutch.

Complaint

First clutch

Gear shifting clutch

First clutch

Gear shifting clutch

Symptom and possible causes

1. Excessively worn clutch shoes.

1. Clutch out of adjustment.

2. Excessively worn clutch plates.

1. Erratic clutch weight movement.

1. Too heavy oil.

2. Clutch out of adjustment.

Remedy

Replace.

Adjust.

Replace.

Replace.

Replace with proper gear oil.

Adjust.

CARBURETOR

Complaint

Starting difficulty.

Idling or low-speed trouble.

Medium or high-speed trouble.

Overflow and fuel level fluctuations.

Symptom and possible causes

1. Clogged starter jet.

2. Clogged starter jet passage.

3. Air leaking from joint between starter plunger and carburetor.

4. Air leaking from carburetor joint or vacuum hose joint.

5. Improperly working starter plunger.

1. Clogged or loose pilot jet.

2. Air leaking from carburetor joint.

3. Clogged pilot outlet port.

4. Clogged bypass port.

5. Starter plunger not fully closed.

1. Clogged main jet.

2. Clogged needle jet.

3. Improperly working throttle valve.

4. Clogged fuel filter.

1. Worn or damaged needle valve.

2. Broken needle valve spring.

3. Improperly working float.

4. Foreign matter on the needle valve.

5. Incorrect float chamber fuel level.

Remedy

Clean.

Clean.

Tighten, adjust, or replace the gasket.

Tighten or replace defective part.

Adjust.

Clean or tighten.

Tighten or replace defective part.

Clean.

Clean.

Adjust.

Clean.

Clean.

Adjust.

Clean or replace.

Replace.

Replace.

Adjust or replace.

Clean or replace the needle valve seat.

Adjust float height.

SERVICING INFORMATION 7-6

CHASSIS

Complaint

Heavy steering.

Wobbly handlebars.

Wobbly front wheel.

Front suspension too soft.

Wobbly rear wheel.

Rear suspension too soft.

Rear suspension too stiff.

Noisy rear suspension.

Symptom and possible causes

1. Overtightened steering stem nut.

2. Broken bearing in steering stem.

3. Distorted steering stem.

4. Not enough pressure in tires.

1. Loss of balance between right and left front forks.

2. Distorted front fork.

3. Distorted front axle or crooked tire.

4. Loose handlebars bolt.

5. Loose steering stem nut.

6. Worn or incorrect tire or wrong tire pressure.

7. Worn bearing/race in steering stem.

1. Distorted wheel rim.

2. Worn front wheel bearing.

3. Defective or incorrect tire.

4. Loose axle nut.

1. Weakened springs.

Remedy

Adjust.

Replace.

Replace.

Adjust.

Ripair or replace.

Repair or replace.

Replace.

Retighten.

Adjust.

Adjust or replace.

Replace.

Replace.

Replace.

Replace.

Retighten.

Replace.

1. Distorted wheel rim.

2. Defective or incorrect tire.

3. Loose axle nut.

1. Weakened shock absorber spring.

2. Leakage of oil from shock absorber.

1. Worn swingarm bushing.

2. Bent shock absorber shaft.

1. Loose bolts on rear suspension.

Replace.

Replace.

Retighten.

Replace.

Replace.

Replace.

Replace.

Retighten.

7-7 SERVICING INFORMATION

BRAKES

Complaint

Insufficient brake power.

Brake squeaking.

Excessive brake lever or pedal stroke.

Brake drags.

Symptom and possible causes

1. Worn shoes or drum.

2. Excessive brake lever play and brake pedal play.

3. Friction surfaces of shoes are dirty with oil or dust.

4. Excessively worn brake drum.

1. Carbon adhesion on shoe surface.

Replace.

Adjust.

Replace.

2. Tilted shoe.

3. Damaged wheel bearing.

4. Loose front or rear axle nut.

5. Brake shoe surface glazed.

6. Worn shoe.

1. Worn brake cam shaft.

2. Excessively worn shoes and/or drum.

Remedy

Replace.

Repair surface with sandpaper.

Correct shoe fitting or replace.

Replace.

Tighten.

Repair surface with sandpaper.

Replace.

Replace.

Replace.

1. Rusty parts.

2. Insufficent brake lever and pedal.

Clean and lubriceate.

Lubricate.

SERVICING INFORMATION 7-8

ELECTRICAL

Complaint

No sparking or poor sparking.

Spark plug soon becomes fouled with carbon.

Spark plug becomes fouled too soon.

Spark plug electrodes overheat or burn.

Generator does not charge.

Generator does charge, but charging rate is below the specification.

Generator overcharges.

Unstable charging.

Starter button is not effective.

Symptom and possible causes

1. Defective ignition coil or CDI unit.

2. Defective spark plug.

3. Defective pick-up coil or generator coil.

4. Open-circuited wiring connections.

1. Too rich mixture.

2. Idling speed set too high.

3. Incorrect gasoline.

4. Dirty air cleaner element.

5. Too cold spark plug.

1. Worn piston rings.

2. Worn piston or cylinder.

3. Excessive clearance of valve stems in valve guides.

4. Worn stem oil seal.

1. Too hot spark plug.

Replace.

Replace.

Replace.

Check and repair.

Adjust carburetor.

Adjust carburetor.

Change.

Clean.

Replace with hot type plug.

Replace.

Replace.

Replace.

Remedy

2. Overheated engine.

3. Loose spark plug.

4. Too lean mixture.

1. Open or short-circuited lead wires, or loose lead connections.

2. Short-circuited, grounded or open generator coil.

3. Short-circuited or punctured regulator/rectifier.

1. Lead wires tend to get shorted or open-circuited or loosely connected at terminals.

2. Grounded or open-circuited generator coil.

3. Defective regulator/rectifier.

4. Defective cell plates in the battery.

1. Internal short-circuit in the battery.

2. Damaged or defective regulator/rectifier.

3. Poorly grounded regulator/rectifier.

Replace.

Replace with cold type plug.

Tune up.

Retighten.

Adjust carburetor.

Repair, replace or retighten.

Replace.

Replace.

Repair or retighten.

Replace.

Replace.

Replace the battery.

Replace the battery.

Replace.

Clean and tighten ground connection.

Repair or replace.

1. Lead wire insulation frayed due to vibration, resulting in intermittent short-circuiting.

2. Internally short-circuited generator coil.

3. Defective regulator/rectifier.

1. Run down battery.

2. Defective switch contacts.

3. Brushes not seating properly on starter motor commutator.

4. Defective starter relay.

5. Defective fuse.

Replace.

Replace.

Repair or replace.

Replace.

Repair or replace.

Replace.

Replace.

7-9 SERVICING INFORMATION

BATTERY

Complaint

“Sulfation”, acidic white powdery substance or spots on surface of cell plates.

Battery runs down quickly.

Battery “sulfation”.

Symptom and possible causes

1. Cracked battery case.

2. Battery has been left in a run-down condition for a long time.

Remedy

Replace the battery.

Replace the battery.

1. Trouble in charging system.

2. Cell plates have lost much of their active material as a result of overcharging.

3. Internal short-circuit in battery.

4. Too low battery voltage.

5. Too old battery.

1. Incorrect charging rate.

(When not in use battery should be checked at least once a month to avoid sulfation.)

2. The battery was left unused in a cold climate for long.

Check the generator, regulator/rectifier and circuit connections and make necessary adjustments to obtain specified charging operation.

Replace the battery, and correct the charging system.

Replace the battery.

Recharge the battery fully.

Replace the battery.

Replace the battery.

Replace the battery if badly sulfated.

WIRING DIAGRAM

O/W O/W

O O

Y/G Y/G

O/W O/W

O O

Y/G Y/G

B/W B/W

B/Y B/Y

O O

R R

O O

R R

B B

R R

R R

R R

B B

B/W B/W

B/Y B/Y

B/Bl B/Bl

O/W O/W

Bl Bl

Bl Bl

R R

Y/G Y/G

R/W R/W

R/W R/W

B/R B/R

R R

B/W B/W

B/Bl B/Bl

B/R B/R

B/Bl B/Bl

B/R B/R

Bl Bl Bl Bl

SERVICING INFORMATION 7-10

7-11 SERVICING INFORMATION

WIRING HARNESS, CABLE AND HOSE ROUTING

WIRING HARNESS ROUTING

Wiring harness

Wiring harness

Clamp

Clamp

Clamp

Wiring harness

Clamp

Wiring harness

Clamp

Wiring harness

Neutral switch

Generator

Clamp

Clamp

To handlebar switch

Starter motor

Clamp

Wiring harness

Neutral switch

Generator

Ignition switch

Ignition coil

Clamp

Ignition switch

Handlebar switch

Ground wire

To neutral switch

Pick-up coil

4.5 N·m

(0.45 kgf-m, 3.5 lb-ft)

Pick-up coil lead wire

SERVICING INFORMATION 7-12

10 N·m

(1.0 kgf-m, 7.0 lb-ft)

10 N·m

(1.0 kgf-m, 7.0 lb-ft)

7-13 SERVICING INFORMATION

CABLE ROUTING

Cable guide

Front brake cable

Starter cable

Throttle cable

Handlebar switch lead wire

Starter cable

Clamp

Cut the tip of clamp as shown

Max. 3 mm

White tape

Clip

Throttle cable

Cable guide

Starter cable

Front brake cable

Front number plate

Clip

Handlebar switch

(R) lead wire

Front brake cable

Throttle cable

Starter cable

Pass the throttle cable and starter cable into the cable guide.

Throttle cable

Cable guide

Front brake cable

Front brake cable

Front brake cable

Front fork cover

SERVICING INFORMATION 7-14

CARBURETOR HOSE ROUTING

Carburetor air vent hose

Yellow mark (upper side)

Pass the crankcase breather hose right side of the air cleaner drain hose.

Crankcase breather hose

White mark

(upper side)

Generator lead wire

Air cleaner drain hose

Carburetor overflow hose

Clamp

Air cleaner clamp inlet cover

Clip

Carburetor overflow hose

Pass the carburetor air vent hose between the starter motor, air cleaner and engine mounting bracket.

Carburetor air vent hose

Crankcase breather hose

7-15 SERVICING INFORMATION

FUEL HOSE AND FUEL TANK BREATHER HOSE ROUTING

Fuel tank breather hose

Fuel tank cap

Fuel tank

Caburetor ripple

Fuel hose

Install the white mark on the fuel hose to upside.

Fuel valve

Clamp

To carburetor

Face the tip of clip to the lower.

Fuel tank cushion

Cut the tip of clamp approx. 10 mm.

HANDLEBAR INSTALLATION

Align the “ ” mark on the grip with the pumched mark on the handlebars.

SERVICING INFORMATION 7-16

110 mm

Clamp

Handlebar pad

Handlebars

Forward

15 mm

7-17 SERVICING INFORMATION

SIDE-STAND INSTALLATION

40 N·m

(4.0 kgf-m, 29.0 lb-ft)

10 N·m

(1.0 kgf-m, 7.0 lb-ft)

REAR BRAKE PEDAL INSTALLATION

Side-stand

Cotter pin

Brake pedal return spring

Brake pedal

SERVICING INFORMATION 7-18

FUEL TANK UPPER COVER CUSHION INSTALLATION

Fuel tank upper cover

Cusion

Cushion

FUEL TANK SIDE COVER CUSHION INSTALLATION

Fuel tank side cover

5 mm

Cushion

7-19 SERVICING INFORMATION

SPECIAL TOOLS

09900-20101

09900-20102

Vernier calipers

09900-20202

Micrometer

(25 – 50 mm)

09900-20205

Micrometer

(1/1 000 mm, 0 – 25 mm)

09900-20530

Cylinder gauge set

09900-20602

Dial gauge

(1/1 000 mm, 1 mm)

09900-20605

Dial calipers

(1/100 mm, 10 – 34 mm)

09900-20607

Dial gauge

(1/100 mm, 10 mm)

09900-20701

Magnetic stand

09900-20803

Thickness gauge

09900-20805

Tire depth gauge

09900-21304

V-block set

(100 mm)

09900-22301

Plasti-gauge

09900-22401

Small bore gauge

(10 – 18 mm)

09900-25008

Multi-circuit tester set

09900-26006

Tachometer

09910-32812

Crankshaft installer

09910-32860

Crankshaft installer spacer

09911-11310

Crankshaft installer attachment

09913-10750

Adaptor

09913-50121

Oil seal remover

09913-60910

Bearing & gear puller

09913-70210

Bearing installer set

09915-63311

Compression gauge adaptor

09915-64512

Compression gauge set

09915-72410

Adaptor

SERVICING INFORMATION 7-20

09915-74511

Oil pressure gauge

09915-74533

Oil pressure gauge adaptor

09916-10911

Valve lapper set

09916-14510

Valve lifter

09916-14521

Valve lifter attachment

09916-34542

Valve guide reamer handle

09916-34570

Valve guide reamer

(5.0 mm)

09916-34580

Valve guide reamer

(10.8 mm)

09916-44310

Valve guide remover/installer

09916-84511

Tweezers

09917-14910

Valve clearance adjusting driver

09920-13120

Crankcase and shaft remover

09920-53740

Clutch sleeve hub holder

09920-33510

Clutch spring compressor

09921-20240

Bearing remover set

09924-84521

Bearing installer set

09930-10121

Spark plug socket wrench set

09930-34951

Rotor remover

09930-40113

Rotor holder

09930-44530

Rotor holder

09940-14911

Steering nut socket wrench

09940-51410

Bearing installer

09940-60113

Spoke nipple wrench

09941-34513

Steering race installer

NOTE:

Before placing order for the special tool, please check for availability.

09941-50111

Bearing remover

7-21 SERVICING INFORMATION

TIGHTENING TORQUE

ENGINE

ITEM

Engine mounting nut

Exhaust pipe bolt

Exhaust cover bolt

Muffler mounting nut

Spark arrester bolt

Intake pipe nut

Engine sprocket cover bolt

Spark plug

Cam chain tensioner bolt

Cylinder nut

Cylinder head nut

Cylinder head bolt

Valve adjuster lock-nut

Cam chain tension adjuster bolt

Camshaft sprocket bolt

Generator cover bolt

Generator cover plug

TDC plug

Generator rotor nut

Generator stator bolt

Pick-up coil set bolt

Generator lead wire clamp bolt

Clutch cover bolt

Main oil gallery plug

Oil filter case nut

Starter clutch bolt

Gearshift arm stopper bolt

Crankcase bolt

Engine oil drain plug

Starter motor mounting bolt

FUEL SYSTEM

Fuel valve bolt

Carburetor mounting bolt

ITEM

1.0

1.9

1.0

1.8

1.0

1.0

1.0

1.0

6.3

1.0

1.1

1.0

1.1

1.1

5.5

1.0

0.45

0.55

1.0

1.1

0.8

1.0

1.1

1.0

1.0

kgf-m

3.1

1.0

0.7

2.3

1.0

kgf-m

0.45

1.0

10

19

10

18

10

10

10

10

63

11

55

10

4.5

10

11

10

11

10

11

10

10

5.5

10

11

8

N·m

31

10

7

23

10

N·m

4.5

10

7.0

7.0

7.0

45.5

7.0

13.5

7.0

13.0

7.0

7.0

8.0

7.0

8.0

8.0

40.0

7.0

3.5

7.0

8.0

7.0

7.0

4.0

7.0

8.0

6.0

lb-ft

22.5

7.0

5.0

16.5

7.0

lb-ft

3.5

7.0

 

SERVICING INFORMATION 7-22

CHASSIS

ITEM

Handlebars set bolt

Front fork upper bracket bolt

Front axle nut

Brake cam lever nut (Front and Rear)

Spoke nipple

Footrest mounting bolt

Side-stand bolt

Side-stand nut

Swingarm pivot nut

Rear shock absorber mounting nut (Upper and Lower)

Rear axle nut

Rear sprocket bolt

50

54

27

23

10

40

42

N·m

23

45

53

3

2

2.3

1.0

4.0

4.2

5.0

5.4

2.7

kgf-m

2.3

4.5

5.3

0.3

0.2

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

13

29

45

65

105

160

Conventional or “4” marked bolt

N·m kgf-m lb-ft

1.5

3

5.5

0.15

0.3

0.55

1.0

2.0

4.0

1.3

2.9

4.5

6.5

10.5

16.0

9.5

21.0

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

16.5

7.0

29.0

30.5

36.0

39.0

19.5

lb-ft

16.5

32.5

38.5

2.0

1.5

)

Conventional bolt “4” marked bolt

“7” marked bolt

7-23 SERVICING INFORMATION

SERVICE DATA

VALVE + GUIDE

ITEM

Valve diam.

Valve clearance (when cold)

Valve guide to valve stem clearance

Valve guide I.D.

Valve stem O.D.

Valve stem deflection

Valve stem runout

Valve head thickness

Valve stem end length

Valve seat width

Valve head radial runout

Valve spring free length

Valve spring tension

IN.

EX.

IN.

EX.

IN.

EX.

IN. & EX.

IN.

EX.

IN. & EX.

STANDARD

22.5

(0.89)

19.0

(0.75)

0.04 – 0.07

(0.0016 – 0.0028)

0.05 – 0.10

(0.0020 – 0.0039)

0.025 – 0.052

(0.0010 – 0.0020)

0.040 – 0.067

(0.0016 – 0.0026)

5.000 – 5.012

(0.1969 – 0.1973)

4.960 – 4.975

(0.1953 – 0.1959)

4.945 – 4.960

(0.1947 – 0.1953)

—

IN. & EX.

IN. & EX.

IN. & EX.

IN. & EX.

IN. & EX.

—

—

—

0.9 – 1.1

(0.035 – 0.043)

—

IN. & EX.

IN. & EX.

—

157 – 181 N (16.0 – 18.5 kgf, 35.3 –

40.8 lbs) at length 25.5 mm (1.00 in)

CAMSHAFT + CYLINDER HEAD

ITEM

Cam height

IN.

Rocker arm I.D.

Rocker arm shaft O.D.

Cylinder head distortion

EX.

IN. & EX.

IN. & EX.

STANDARD

27.39 – 27.43

(1.078 – 1.08)

27.25 – 27.29

(1.073 – 1.074)

10.003 – 10.018

(0.3938 – 0.3944)

9.981 – 9.990

(0.3930 – 0.3933)

—

—

—

—

—

—

0.35

(0.014)

0.05

(0.002)

0.5

(0.02)

2.2

(0.09)

—

0.03

(0.001)

34.5

(1.36)

—

Unit: mm (in)

LIMIT

—

—

—

—

Unit: mm (in)

LIMIT

27.09

(1.067)

26.95

(1.061)

—

—

0.05

(0.002)

SERVICING INFORMATION 7-24

CYLINDER + PISTON + PISTON RING

ITEM

Compression pressure

STANDARD

1 300 – 1 700 kPa

(13 – 17 kgf/cm², 185– 242 psi)

Piston to cylinder clearance

Cylinder bore

Piston diam.

Cylinder distortion

Piston ring free end gap

Piston ring end gap

Piston ring to groove clearance

0.025 – 0.035

(0.0010 – 0.0014)

48.000 – 48.015

(1.8898 – 1.8904)

47.970 – 47.985

(1.8886 – 1.8892)

Measure at 10 mm (0.4 in) from the skirt end.

—

1st

2nd

1st

2nd

1st

R

R

Approx.

5.0

(0.20)

Approx.

6.6

(0.26)

0.10 – 0.25

(0.004 – 0.010)

0.10 – 0.25

(0.004 – 0.010)

—

Piston ring groove width

Piston ring thickness

Piston pin bore I.D

Piston pin O.D.

2nd

1st

2nd

Oil

1st

2nd

—

1.01 – 1.03

(0.0398 – 0.0405)

1.21 – 1.23

(0.0476 – 0.0484)

2.01 – 2.03

(0.0791 – 0.0799)

0.97 – 0.99

(0.0382 – 0.0390)

1.16 – 1.18

(0.0457 – 0.0465)

13.002 – 13.008

(0.5119 – 0.5121)

12.992 – 13.000

(0.5115 – 0.5118)

Unit: mm (in)

LIMIT

1 100 kPa

(11 kgf/cm²,

156 psi)

0.120

(0.0047)

48.105

(1.8939)

47.880

(1.8850)

0.05

(0.002)

4.0

(0.16)

5.3

(0.21)

0.5

(0.02)

0.5

(0.02)

0.180

(0.0071)

0.150

(0.0059)

—

—

—

—

—

13.030

(0.5130)

12.980

(0.5110)

7-25 SERVICING INFORMATION

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

OIL PUMP

ITEM

Oil pressure (at 60°C, 140°F)

STANDARD

13.006 – 13.014

(0.5120 – 0.5124)

—

0.10 – 0.45

(0.004 – 0.018)

13.95 – 14.00

(0.549 – 0.551)

38.0 ± 0.1

(1.496 ± 0.004)

—

STANDARD

Above 15 kPa (0.15 kgf/cm², 2.1 psi)

Below 40 kPa (0.4 kgf/cm², 5.7 psi) at 3 000 r/min

CLUTCH

ITEM

Clutch release screw

Clutch plate thickness

Clutch plate claw width

Clutch wheel I.D.

Clutch shoe thickness

Clutch engagement

Clutch lock-up

Drive

Driven No. 1

Driven No. 2

Drive

Driven No. 1

Driven No. 2

STANDARD

1/8 turn back

2.5 – 2.7

(0.098 – 0.106)

2.02 – 2.18

(0.080 – 0.086)

2.5 – 2.7

(0.098 – 0.106)

15.65 – 15.95

(0.616 – 0.628)

11.8 – 12.0

(0.465 – 0.472)

11.7 – 11.9

(0.460 – 0.469)

105.00 – 105.15

(4.133 – 4.140)

—

1 700 – 2 100 r/min

2 900 – 3 500 r/min

Unit: mm (in)

LIMIT

13.040

(0.5134)

3.0

(0.12)

1.0

(0.04)

—

—

0.08

(0.003)

LIMIT

—

Unit: mm (in)

LIMIT

—

2.2

(0.092)

1.72

(0.068)

2.2

(0.092)

15.15

(0.596)

11.3

(0.44)

11.2

(0.44)

105.50

(4.154)

No groove at any part

—

—

SERVICING INFORMATION 7-26

DRIVE TRAIN + DRIVE CHAIN

ITEM

Primary reduction ratio

Final reduction ratio

Gear ratios Low

2nd

Top

Gearshift fork to groove clearance

No.1 & No. 2

Gearshift fork groove width

No.1 & No. 2

Gearshift fork thickness

Drive chain

No.1 & No. 2

Type

Links

20-pitch length

Drive chain slack

STANDARD

3.823 (65/17)

2.538 (33/13)

3.400 (34/10)

1.812 (29/16)

1.200 (24/20)

0.1 – 0.3

(0.004 – 0.012)

4.5 – 4.6

(0.177 – 0.181)

4.3 – 4.4

(0.169 – 0.173)

D.I.D 428

78

—

Unit: mm (in) (Except ratio)

LIMIT

—

—

—

—

—

0.5

(0.02)

—

—

—

—

259.0

(10.20)

25 – 35

(1.0 – 1.4)

—

CARBURETOR

Carburetor type

ITEM

Bore size

I.D. No.

Idle r/min.

Float height

Main jet

Jet needle

Needle jet

Pilot jet

(M.J.)

(J.N.)

(N.J.)

(P.J.)

Air screw (A.S.)

Throttle cable play

STANDARD/SPECIFICATION

MIKUNI VM13SH

13 mm (0.5 in)

14H0

1 600 ± 100 r/min.

23.4 ± 1.0 mm (0.92 ± 0.04 in)

#55

3L43

E-5M

#17.5

PRE-SET (2 turns back)

2.0 – 4.0 mm (0.08 – 0.16 in)

7-27 SERVICING INFORMATION

ELECTRICAL

Spark plug

ITEM

Spark performance

Ignition coil resistance

Type

Gap

STANDARD/SPECIFICATION

NGK: CR7HSA

DENSO: U22FSR-U

0.6 – 0.7

(0.024 – 0.028)

Over 8 (0.3) at 1 atm.

Primary 0.1 – 0.8

Ω

Secondary 13 – 20 k Ω

Ignition coil primary peak voltage

150 V and more

Pick-up coil peak voltage

Generator coil resistance Charging

Generator no-load voltage

(when engine is cold)

Pick-up coil

Regulated voltage(Charging output)

Starter relay resistance

Battery Type designation

Capacity

Fuse size

Starter motor brush length

1.2 V and more

0.6 – 2.0 Ω

150 – 240

Ω

30 V (AC) and more at 5 000 r/min.

Standard

Limit

13.5 – 15.2 V at 5 000 r/min

70 – 90 Ω

YT4B-BS

12 V 8.28 kC (2.3 Ah)/10 HR

10 A

6.0 (0.24)

3.5 (0.14)

Unit: mm (in)

NOTE

Terminal –

Terminal

Plug cap –

Terminal

+ : Ground,

: B/Y

+ : B/Bl,

: Ground

B/R – Ground

B/BI – Ground

BRAKE + WHEEL

ITEM

Front brake lever play

Rear brake pedal free travel

Brake drum I.D.

Wheel rim runout

Wheel axle runout

Wheel rim size

Tire size

Tire tread depth

SUSPENSION

ITEM

Front fork stroke

Front fork spring free length

Rear wheel travel

Swingarm pivot shaft runout

Front

Rear

Axial

Radial

Front

Rear

Front

Rear

Front

Rear

Front

Rear

STANDARD

15 –25

(0.6 – 1.0)

15 – 20

(0.6 – 0.8)

—

—

—

—

—

—

10 × 1.40

10 × 1.40

2.50 – 10 33J

2.50 – 10 33J

—

—

STANDARD

96 (3.8)

157.8 (6.21)

76 (3.0)

—

SERVICING INFORMATION 7-28

Unit: mm (in)

LIMIT

—

—

80.7 (3.18)

80.7 (3.18)

2.0

(0.08)

2.0

(0.08)

0.25

(0.010)

0.25

(0.010)

—

—

—

—

4.0

(0.16)

4.0

(0.16)

Unit: mm (in)

LIMIT

—

154 (6.1)

—

0.6 (0.02)

7-29 SERVICING INFORMATION

TIRE PRESSURE

COLD INFLATION

TIRE PRESSURE

FRONT

REAR

FUEL + OIL

ITEM

Fuel type

Fuel tank capacity

Engine oil type

Engine oil capacity kPa

100

125 kgf/cm

2

1.0

1.25

psi

14

18

SPECIFICATION

Use only unleaded gasoline of at least 87 pump octane ( R + M

2

) or 91 octane or higher rated by the

Research Methrod.

Gasoline containing MTBE (Methyl Tertiary Butyl

Ether), less than 10 % ethanol, or less than 5 % methanol with appropriate cosolvents and corrosion inhibitor is permissible.

Including reserve

Reserve

3.0 L (0.8/0.7 US/lmp gal)

0.8 L (0.2/0.2 US/lmp gal)

SAE 10W-40, API SF/SG or SH/SJ with JASO MA

Change 700 ml (0.7/0.6 US/lmp qt)

Overhaul 800 ml (0.8/0.7 US/lmp qt)

NOTE

Prepared by

May, 2007

Part No.99500-40030-03E

Printed in USA

196

TOP

Printed in USA

K8

99500-40030-03E DR-Z70K8_03E SERVICE MANUAL 2007. 5. 15 for PS printing

BOTTOM

9 9 5 0 0 - 4 0 0 3 0 - 0 3 E