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FOREWORD
This manual contains an introductory description on the SUZUKI GZ250 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 as a guide for proper inspection and service. This manual will help you know the motorcycle better so that you can assure your customers of fast and reliable service.
This manual has been prepared on the basis of the latest specifications at the time of publication. If modifications have been made since then, differences may exist between the content of this manual and the actual motorcycle.
Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual motorcycle exactly in detail. This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized
SUZUKI motorcycle dealer to help you.
WARNING
Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the service described in this manual. Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider and passenger.
GROUP INDEX
GENERAL INFORMATION
PERIODIC MAINTENANCE
ENGINE
FUEL AND LUBRICATION
SYSTEM
CHASSIS
ELECTRICAL SYSTEM
SERVICING INFORMATION
SUZUKI MOTOR CORPORATION
Motorcycle Service Department
© COPYRIGHT SUZUKI MOTOR CORPORATION 1998
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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
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SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table.
SYMBOL
DEFINITION
Torque cont rol required.
Data beside it indicates specified torque.
Apply oil. Use engine oil unless otherwise specified.
Apply molybdenum oil solution (mix ture of engine oil and SUZUKI MOLY
PASTE in a ratio of 1 : 1).
Apply SUZUK I SUPE R GREASE
"A".
99000-25010
SYMBO L DEFINITION
Apply THREA D LOCK "1360".
99000-32130
Apply or use brake fluid.
Measure in voltage range.
Measure in resistance range.
Measure in current range.
Apply SUZUK I SILICONE GREASE.
99000-25100
Apply SUZUK I MOLY PASTE.
99000-25140
Apply SUZUK I BOND "1215".
99000-31110
Apply THREA D LOCK SUPE R
"1303".
99000-32030
Apply THREA D LOCK "1342".
99000-32050
Measure in diode test range.
Measure in continuity test range.
Use special tool.
Use fork oil. 99000-
99001-SS8
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GENERAL INFORMATION
--------------------------------------------
CONTENTS
------------------------------------------------- 1
WARNING/CAUTION/NOTE
.......................................................................
1- 1
GENERAL PRECAUTIONS
.........................................................................
1- 1
SUZUKI GZ250X ('99-MODEL)
.................................................................
1-3
SERIAL NUMBER LOCATION
..................................................................
1-3
FUEL AND OIL RECOMMENDATIONS
....................................................
1-3
FUEL
.........................................................................................................
1-3
ENGINE OIL
..........................................................................................
1-4
BRAKE FLUID
.......................................................................................
1-4
FRONT FORK OIL
...................................................................................
1-4
BREAK-IN PROCEDURES
........................................................................
1-4
INFORMATION LABELS
............................................................................
1-5
SPECIFICATIONS
.....................................................................................
1-6
COUNTRY AND AREA CODES
...............................................................
1-8
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1-1 GENERAL INFORMATION
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words.
WARNING
Indicates a potential hazard that could result in death or injury.
CAUTION
Indicates a potential hazard that could result in motorcycle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the
WARNINGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a particular service operation, ask a more experienced mechanic for advice.
GENERAL PRECAUTIONS
WARNING
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 well ventilated and that you follow all of the 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 fuel, oil, exhaust or brake systems, check all of the lines and fittings related to the system for leaks.
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GENERAL INFORMATION 1-2
CAUTION
* 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.
* Be sure to use special tools when instructed.
* Make sure that all parts used in reassembly are clean. Lubricate them when spec ified.
* Use the specified lubricant, bond, or sealant.
* When removing the battery, disconnect the negative cable first and then the positive cable.
* When reconnecting the battery, connect the positive cable first and then the negative cable, and cover the positive terminal with the terminal cover.
* When performing service to electrical parts, disconnect the battery negative cable un less the service procedure requires the battery power.
* When tightening cylinder head and crankcase bolts and nuts, tighten the larger sizes first. Always tighten the bolts and nuts from the inside working out, in a crisscross pattern and to the specified tightening torque.
* Whenever you remove oil seals, gaskets, packing, O-rings, self-locking nuts, locking washers, 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.
CAUTION
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* To protect the environment, do not unlawfully dispose of used motor oil and all other fluids, batteries, and tires.
* To protect the earth's natural resouces, properly dispose of used motorcycles and parts.
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1-3 GENERAL INFORMATION
SUZUKI GZ250X ('99-MODEL)
SERIAL NUMBER LOCATION
The frame serial number or V.I.N. (Vehicle Identification Number) is stamped on the right side of the steering head pipe. The engine serial number is located on the left side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts.
FUEL AND OIL RECOMMENDATIONS
FUEL
Use unleaded gasoline that is graded 91 octane or higher.
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GENERAL INFORMATION
1-4
ENGINE OIL
Use only oils which are rated SF or SG under the API classification. The recommended viscosity is SAE 10W/40. If
SAE 10W/40 engine oil is not available, select an alternative according to the chart.
BRAKE FLUID
Specification and classification: DOT 4
WARNING
This motorcycle uses a glycol-based brake fluid. Do not use or mix different types of brake fluid such as silicone-based and petroleum-based fluids for refilling the system, otherwise serious damage will result to the brake system.
Never use any brake fluid taken from old, used or unsealed containers.
Never re-use brake fluid left over from a last servicing or which has been stored for a long period of time.
FRONT FORK OIL
Use SUZUKI fork oil SS-08 (#10).
BREAK-IN PROCEDURES
During manufacturing only the best possible materials are used and all machined parts are finished to a very high standard. It is still necessary to allow the moving parts to "BREAK-IN" before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. The general rules are as follows.
• Keep to this break-in throttle position.
Initial 800 km (500 miles) : Less than 1/2 throttle
Up to 1 600 km (1 000 miles): Less than 3/4 throttle
• Upon reaching an odometer reading of 1 600 km you can subject the motorcycle to full throttle operation for short periods of time.
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GENERAL INFORMATION 1-6
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length .........................................
Overall width ............................................
Overall height ..........................................
Wheelbase ................................................
Ground clearance ......................................
Seat height ................................................
Dry mass .................................................
ENGINE
Type .........................................................
Number of cylinder.....................................
Bore..........................................................
Stroke ......................................................
Displacement ............................................
Compression ratio......................................
Carburetor ...............................................
Air cleaner .................................................
Starter system ...........................................
Lubrication system ....................................
TRANSMISSION
Clutch ......................................................
Transmission ...........................................
Gearshift pattern ........................................
Primary reduction ratio .............................
Final reduction ratio ...................................
Gear ratios, Low.......................................
2nd
.....................................
3rd ......................................
4th.......................................
Top ...................................
Drive chain ................................................
2 160 mm (85.0 in)
815 mm (32.1 in)
1 090 mm (42.9 in)
1 450 mm (57.1 in)
125 mm ( 4.9 in)
680 mm (27.8 in)
137 kg (302 lbs)
Four-stroke, air-cooled, OHC
1
72.0 mm (2. 835 in)
61.2 mm (2. 409 in)
249 cm
3
(15.2 cu. in)
9.0 : 1
MIKUNI BSR32SS, single
Non-woven fabric element
Electric
Wet sump
Wet multi-plate type
5-speed constant mesh
1-down, 4-up
3.238 (68/21)
2.733 (41/15)
2.636
(29/11)
1.687 (27/16)
1.263 (24/19)
1.000 (20/20)
0.818 (18/22)
DID 520VC5, 110 links
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1-7 GENERAL INFORMATION
ELECTRICAL
Ignition type ......................................................... Electronic ignition (Transistorized)
Ignition timing .................................................... 10° B. T.D.C. at 1 300 r/min
Spark plug .......................................................... NGK DR8EA or DE NSO X24ES R-U
Battery ................................................................. 12V 21.6 kC (6 Ah)/ 10 HR
Generat or............................................................. Three-phase A.C. generator
Fuse .................................................................... 20/15/ 15/15/ 10/10A
Headlight ............................................................. 12V 60/55W
Position light ...................................................... 12V 4W ....... Except for E-03, -24, -28, -33
Brake light/ Taillight .............................................. 12V 21/5W
Front turn signal light/Running light ........................ 12V 21/5W ....... E-03, -28, -33
Turn signal light ................................................. 12V 21W
Speedometer light................................................. 12V 1.7W
Neut ral indicator light ............................................ 12V 3.4W
Turn signal indic ator light ...................................... 12V 3.4W
High beam indicator light ..................................... 12V 1.7W
CHASSIS
Front suspension ............................................... Telescopic, coil spring, oil damped
Rear suspension................................................... Swingarm type, coil spring, oil damped, spring preload 5-way adjustable
Front fork stroke ................................................... 120 mm (4.7 in)
Rear wheel travel ................................................. 90 mm (3.5 in)
Steering angle ...................................................... 40° (right and left)
Caster ................................................................. 32° 30'
Trail ................................................................... 140 mm (5.5 in)
Turning radius ..................................................... 2.6 m (8.5 ft )
Front brake .......................................................... Disc brake
Rear brake ........................................................... Internal expanding
Front tire size ..................................................... 110/90-16 59P
Rear tire size........................................................ 130/90-15M/ C 66P
CAPACITIES
Fuel tank, including reserve................................... 14 L (3.7/3.1 US/ Imp gal) reserve ............................................. 2.9 L (0.8/0. 6 US/Imp gal)
Engine oil, oil change ........................................ 1 300 ml (1.4/1.1 US/ Imp qt ) with filter change .............................. 1 400 ml (1.5/1.2 US/ Imp qt ) overhaul .......................................... 1 700 ml (1.8/1.5 US/ Imp qt )
Front fork oil (each leg) ...................................... 369 ml (12.5/ 13.0 US/ Imp oz)
Specifications are subject to change without notice.
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COUNTRY AND AREA CODES
The following codes stand for the applicable country(-ies) and area(-s).
GENERAL INFORMATION 1- 8
CODE
E-01
E-02
E-03
E-04
E-17
E-22
E-24
E-25
E-28
E-33
E-34
COUNTRY OR AREA
General
UK
U.S.A. (Except for California)
Franc e
Sweden, Finland (E-15), Norway (E-16), Denmark (E -26)
Germany
Australia
Netherlands
Canada
California (U.S.A.)
Italy, Belgium (E -21), Spain (E-53)
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PERIODIC MAINTENANCE
--------------------------------------------
CONTENTS
---------------------------------------------
PERIODIC MAINTENANCE SCHEDULE
..................................................
2- 1
PERIODIC MAINTENANCE CHART
......................................................
2- 1
LUBRICATION POINTS
........................................................................
2-2
MAINTENANCE AND TUNE-UP PROCEDURES
..................................
2-3
EXHAUST PIPE BOLTS AND MUFFLER MOUNTING BOLTS
...........
2-3
AIR CLEANER
.........................................................................................
2- 3
VALVE CLEARANCE
............................................................................
2-4
SPARK PLUG
..........................................................................................
2- 6
FUEL HOSE
..............................................................................................
2- 7
ENGINE IDLE SPEED
.............................................................................
2- 7
THROTTLE CABLE PLAY
......................................................................
2- 7
STARTER PLUNGER CABLE PLAY
.....................................................
2-9
CLUTCH
....................................................................................................
2-9
ENGINE OIL AND OIL FILTER
..............................................................
2- 9
DRIVE CHAIN
........................................................................................... 2-70
BRAKES
....................................................................................................
2-12
TIRE
..........................................................................................................
2-15
STEERING
.................................................................................................
2-15
FRONT FORK
...........................................................................................
2-16
REAR SUSPENSION
...............................................................................
2-16
CHASSIS BOLTS AND NUTS
...............................................................
2-16
COMPRESSION PRESSURE CHECK
.....................................................
2-18
OIL PRESSURE CHECK
............................................................................
2-19
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2-1 PERIODIC MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE
The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometers and months, and are dependant on whichever comes first.
NOTE:
More frequent servicing may be performed on motorcycles that are used under severe conditions.
PERIODIC MAINTENANCE CHART
Interval
Item km miles months
Exhaust pipe bolts and muffler mounting
bolts
Air cleaner element
Valve clearance
Spark plug
Fuel hose
Engine idle speed
Throttle cable play
Clutch
Engine oil
Engine oil filter
Drive chain
Brake s
Brake hose
Brake fluid
Tires
Steering
Front fork
Rear suspension
Chassis bolts and nuts
1 000
600
3
5 000
3
000
15
10 000
6
000
30
15 000
9 500
45
- T T
Clean every 3 000 km (2 000 miles).
T
I
-
I
I
I
R
I
I
- I I I
I
I
-
R
Replace every 4 years.
I I
I
I
R
I
I
R
I
I
I
R
R - R -
I
I I I
Clean and lubricate every 1 000 km (600 miles).
I
I I I
- I I I
-
-
-
I
-
T
Replace every 4 years.
I I
Replace every 2 years.
I
-
I
I
-
-
T
I
I
T
I
I
-
-
-
T
NOTE:
I: Inspection and adjust, clean, lubricate or replace as necessary
C: Clean R: Replace T: Tighten
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PERIODIC MAINTENANCE 2-2
LUBRICATION POINTS
Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below.
Side-stand pivot and spring hook
Drive chain
Brake pedal pivot
Clutch lever holder
Brake lever holder
NOTE:
* Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.
* Lubricate exposed parts which are subject to rust, with a rust preventative spray especially whenever the motorcycle has been operated under wet or rainy condition.
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2-3 PERIODIC MAINTENANCE
MAINTENANCE AND TUNE-UP PROCEDURES
This section describes the servicing procedures for each item in the Periodic Maintenance chart.
EXHAUST PIPE BOLTS AND MUFFLER
MOUNTING BOLTS
Tighten every 5 000 km (3 000 miles, 15 months).
• Tighten the exhaust pipe bolts and muffler mounting bolt to the specified torque.
Exhaust pipe bolt : 14 N ■ m (1.4 kg-m, 10.0 Ib-ft)
Muffler mounting bolt : 29 N ■ m (2.9 kg-m, 21.0 Ib-ft)
AIR CLEANER
Clean every 3 000 km (2 000 miles).
If the air cleaner is clogged with dust, intake resistance will increase, resulting in a decrease in engine output and an increase in fuel consumption. Check and clean the air cleaner element in the following manner.
• Remove the front seat. (See p. 5-1.)
• Remove the left frame cover. (See p. 5-1.)
• Remove the air cleaner element .
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PERIODIC MAINTENANCE 2-4
• Carefully use compressed air to clean the air cleaner element.
CAUTION CAUTION _________________________________
Always apply compressed air to the outside of the air cleaner element. If compressed air is applied to the inside, dirt will be forced into the pores of the air cleaner element, restricting air flow through the air cleaner element.
• Reinstall the cleaned or new air cleaner element in the reverse order of removal.
• When installing the air cleaner element into the air cleaner case, align the triangle marks on the air cleaner element and the air cleaner case.
CAUTION
If driving under dusty conditions, clean the air cleaner element more frequently. The surest way to accelerate engine wear is to operate the engine without the element or 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!
NOTE:
When cleaning the air cleaner element, remove the plug and drain any water from the air cleaner drain hose.
VALVE CLEARANCE
Inspect initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 miles, 15 months) thereafter.
INSPECTION
• Remove the front seat. (See p. 5-1.)
• Remove the fuel tank. (See p. 4-1.)
• Remove the cylinder head cover left cap
• Disconnect the spark plug cap and remove the spark plug.
09930-10121: Spark plug socket wrench set
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2-5 PERIODIC MAINTENANCE
Remove the valve inspection caps
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 removed for servicing.
Valve clearance (when cold):
IN. : 0.03-0.08 mm (0.001-0.003 in)
EX.: 0.08-0.13 mm (0.003-0.005 in)
NOTE:
* The piston must be at top dead center (TDC) on the compression stroke in order to check or adjust the valve clearance.
* The valve clearance should only be checked when the engine is cold.
* Remove the valve timing inspection plug and generator cover cap
Rotate the crankshaft with a box wrench to set the piston at top dead center (TDC) on the compression stroke.
(Rotate the crankshaft until the "T" line on the generator rotor is aligned with the triangle mark on the generator cover.)
Insert a thickness gauge into the clearance between the valve stem end and the adjusting screw on the rocker arm.
09900-20803: Thickness gauge
If the clearance is out of specification, adjust it to specification as follows.
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ADJUSTMENT
The clearance is adjusted using the special tool and offset wrench.
• Loosen the locknuts
• Insert a thickness gauge between the valve stem end and the adjusting screw on the rocker arm.
• Adjust the valve clearance by turning the adjusting screw
using the special tool while holding the locknuts
09917-14920: Valve adjuster wrench
CAUTION
Both the right and left valve clearances should be as closely as possible.
• After the adjustment is completed, tighten the locknut securely.
• Rotate the crankshaft 720° with a box wrench and check that the clearance is within specification.
SPARK PLUG
Inspect every 5 000 km (3 000 miles, 15 months).
Replace every 10 000 km (6 000 miles, 30 months).
Neglecting the spark plug eventually leads to difficult starting and poor engine performance. If the spark plug is used for a long period, the electrode gradually bums away and carbon builds up along the inside part of the spark plug. In accordance with the Periodic Maintenance chart, the spark plug should be inspected, cleaned and regapped at the recommended intervals.
• Remove the cylinder head cover left cap.
• Disconnect the spark plug cap and remove the spark plug.
09930-10121: Spark plug socket wrench set
• Carbon deposits on the spark plug will prevent good sparking and may cause the engine to misfire. Be sure to clean the carbon deposits off periodically.
If the center electrode is fairly worn down, the spark plug should be replaced and the spark plug gap set to the specification using a thickness gauge.
09900-20803: Thickness gauge
Spark plug gap: 0.6-0.7 mm (0.024-0.028 in)
PERIODIC MAINTENA NCE 2-6
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2-7 PERIODIC MAINTENANCE
Check the spark plug for burns. If any abnormalities are found, replace the spark plug as indicated below.
NGK
DR7EA
DR8EA
DR9EA
DENSO
Remarks
X22ESR-U
If the standard spark plug is apt to get wet, replace wit h this plug.
X24ESR-U Standard
X27ESR-U
If the standard spark plug is apt to overheat, replace wit h this plug.
CAUTION
Confirm the thread size and reach when replacing the spark plug. If the reach is too short, carbon will be deposited on the screw portion of the plug hole and engine damage may result.
CAUTION
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 using the special tool.
Spark plug: 18 N-m (1.8 kg-m, 13.0 Ib-ft)
09930-10121: Spark plug socket wrench set
FUEL HOSE
Inspect every 5 000 km (3 000 miles, 15 months).
Replace every 4 years.
ENGINE IDLE SPEED
Inspect initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 miles, 15 months) thereafter.
• Adjust the throttle cable play. (See p. 2-8.)
• Warm up the engine.
NOTE:
Make this adjustment when the engine is hot.
• Connect an electric tachometer to the high tension cord.
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• Start the engine, turn the throttle stop screw and set the engine idle speed as follows.
Engine idle speed:
1 300 ± 50 r/min .... For E-03, -28, -33
1 300 ±100 r/min ..... For the others
09900-26006: Tachometer
THROTTLE CABLE PLAY
Inspect initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 miles, 15 months) thereafter.
Adjust the throttle cable play steps.
with the following three
First step:
• Loosen the lock nut of the throttle returning cable and turn in the adjuster fully into the threads.
Second step:
• Loosen the lock nut of the throttle pulling cable
• Turn the adjuster in or out until the throttle cable play
should be 2.0-4.0 mm (0.08-0.16 in) at the throttle grip.
• Tighten the lock nut while holding the adjuster
Third step:
• While holding the throttle grip at the fully closed position, slowly turn out the adjuster of the throttle returning cable to feel resistance.
• Tighten the lock nut while holding the adjuster
Throttle cable play : 2.0-4.0 mm (0.08-0.16 in)
WARNING
After the adjustment is completed, check that handlebar movement does not raise the engine idle speed and that the throttle grip returns smoothly and automatically.
NOTE:
Major adjustment can be made by the carburetor side adjuster.
PERIODIC MAINTENANCE 2-8
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2-9 PERIODIC MAINTENANCE
STARTER PLUNGER CABLE PLAY
Starter plunger cable play should be 0.5-1.0 mm
(0.02-0.04 in) as shown. If the play is incorrect, adjust it as follows:
• Loosen the lock nut and turn the adjuster in or out until the specified play is obtained.
• Tighten the lock nut while holding the adjuster
Starter plunger cable play 0.5-1.0 mm
(0.02-0.04 in)
CLUTCH
Inspect every 5 000 km (3 000 miles, 15 months).
• Loosen the lock nut and turn the adjuster fully in.
• Loosen the lock nut and turn the adjuster until the clutch lever play is within specification.
Clutch lever play : 10-15 mm (0.4-0.6 in)
• Tighten the lock nuts
ENGINE OIL AND OIL FILTER
(ENGINE OIL)
Replace initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 miles, 15 months) thereafter.
(OIL FILTER)
Replace initially at 1 000 km (600 miles, 3 months) and every 10 000 km (6 000 miles, 30 months) thereafter.
The engine oil should be changed while the engine is warm. Oil filter replacement at the above intervals should be done together with the engine oil change.
ENGINE OIL REPLACEMENT
• Keep the motorcycle upright.
• Place an oil pan below the engine, and drain the engine oil by removing the engine oil drain plug and oil filler cap .
• Tighten the oil drain plug to the specified torque, and pour new oil through the oil filler. When performing an oil change (without oil filter replacement), the engine will hold about 1 300 ml (1.4/1.1 US/Imp qt) of oil. Use SF or
SG classified (API) engine oil with a viscosity rating of
10W-40 (SAE).
Oil drain plug: 28 N-m (2.8 kg-m, 20.0 Ib-ft)
• Install the oil filler cap
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• Start up the engine and allow it to run for a few minutes at idling speed.
• Turn off the engine and wait about one minute, then check the oil level through the inspection window . If the level is below the "F" mark, add oil to the proper level.
OIL FILTER REPLACEMENT
• Drain the engine oil as described in the engine oil replacement procedure.
• Remove the oil filter cap by removing the nuts.
• Remove the oil filter and install a new one.
• Install the oil filter cap and tighten the nuts securely.
NOTE:
Before installing the new oil filter and oil filter cap, make sure that the spring and new O-rings installed correctly.
are
• Add new engine oil and check the oil level as described in the engine oil replacement procedure.
Oil viscosity and classification:
10W/40 (SAE)/SF or SG (API)
NECESSARY AMOUNT OF ENGINE OIL
Oil change : 1 300 ml (1.4/1.1 US/Imp qt)
Oil and filter change: 1 400 ml (1.5/1.2 US/Imp qt)
Engine overhaul : 1 700 ml (1.8/1.5 US/Imp qt)
DRIVE CHAIN
Inspect initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 miles, 15 months) thereafter. Clean and lubricate every 1 000 km (600 miles).
Visually inspect the drive chain for the possible defects listed below. (Support the motorcycle by a jack and a wooden block, turn the rear wheel slowly by hand with the transmission shifted to Neutral.)
• Loose pins * Excessive wear
• Damaged rollers
• Dry or rusted links
• Twisted or seized links
* Kinked or binding links
* Missing O-ring seals
If any defects are found, the drive chain must be replaced.
The standard drive chain is DID520VC5. SUZUKI recommends to use this standard drive chain as a replacement.
CAUTION __________________________________
The standard drive chain is DID520VC5. SUZUKI recommends to use this standard drive chain as a
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PERIODIC MAINTENANCE 2-10
replacement.
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2-11 PERIODIC MAINTENANCE
CHECKING AND ADJUSTING
• Remove the rear axle cotter pin. (For E-28 model)
• Loosen the rear axle nut
• Tense the drive chain fully by turning chain adjuster nuts
• Count out 21 pins (20-pitch) on the chain measure the distance between the two points. If the distance exceeds the service limit, the chain must be replaced.
Drive chain 20-pitch length: 319.4 mm (12.57 in)
NOTE:
When replacing the drive chain, replace the drive chain and sprockets as a set.
• Place the motorcycle on the side-stand.
• Loosen both chain adjuster nuts until the chain has 5-15 mm (0.2-0.6 in) of slack at the middle of the chain bet ween the engine and rear sprockets as shown. The reference marks must be at the same position on the scale to ensure that the front and rear wheels are cor rectly aligned.
Drive chain slack: 5-15 mm (0.2-0.6 in)
• After adjusting the drive chain, tighten the rear axle nut
to the specified torque.
Rear axle nut:
65 N-m (6.5 kg-m, 47.0 Ib-ft) ........ For E-03, -28, -33
78 N-m (7.8 kg-m, 56.5 Ib-ft) ........ For the others
• Recheck the chain slack after tightening the axle nut and readjust if necessary.
* Tighten both chain adjuster nuts securely.
• Install the new cotter pin. (For E-03, -28, -33 models)
CLEANING AND LUBRICATING
• Clean the drive chain with kerosine. If the drive chain tends to rust quickly, the intervals must be shortened.
CAUTION
Do not use trichloroethylene, gasoline or any similar solvent.
These fluids have too great a dissolving power for this chain and they can damage the O-rings. Use only kerosine to clean the drive chain.
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• After cleaning and drying the chain, oil it with a heavyweight engine oil.
CAUTION
Do not use any oil sold commercially as "drive chain oil", this type of oil can such oil can damage the "0"-rings (or seals).
BRAKES
(BRAKE)
Inspect initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 miles, 15 months) thereafter.
(BRAKE HOSE AND BRAKE FLUID)
Inspect every 5 000 km (3 000 miles, 15 months).
Replace hose every 4 years. Replace fluid every 2 years.
BRAKE FLUID LEVEL
• Keep the motorcycle upright and place the handlebars straight.
• Check the brake fluid level by observing the lower limit line on the front brake fluid reservoir.
• When the brake fluid level is below the lower limit line replenish with brake fluid that meets the following specification.
Specification and classification: DOT 4
WARNING
The brake system of this motorcycle is filled with a glycol-based brake fluid. Do not use or mix different types of fluid such as siliconebased and petroleum-based fluids. Do not use any brake fluid taken from old, used or unsealed containers. Never re-use brake fluid left over from the last servicing or stored for a long period of time.
Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces. Check the brake hose and hose joints for cracks and oil leakage.
PERIODIC MAINTENANCE 2-12
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2-13 PERIODIC MAINTENANCE
FRONT BRAKE PADS
The extent of brake pad wear can be checked by observing the limit line on the pad. When the wear exceeds the limit line, replace the pads with new ones. (See p. 5-8.)
A CAUTION
Replace the brake pad as a set, otherwise braking performance will be adversely affected.
AIR BLEEDING THE BRAKE FLUID CIRCUIT
Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the brake caliper. The presence of air is indicated by "sponginess" of the brake lever and also by lack of braking force. Considering the danger to which such trapped air exposes the machine and rider, it is essential that, after remounting the brake and restoring the brake system to the normal condition, the brake fluid circuit be purged of air in the following manner:
• Fill the master cylinder reservoir to top of the inspection window. Replace the reservoir cap to prevent dirt from entering.
• Attach a hose to the air bleeder valve, and insert the free end of the hose into a receptacle.
• Bleed air from the brake system.
• Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it. Loosen the bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle, this will remove the tension of the brake lever causing it to touch the handlebar grip. Then, close the air bleeder valve, pump and squeeze the brake lever, and open the valve. Repeat this process until the fluid flowing into the receptacle no longer contains air bubbles.
NOTE:
While bleeding the brake system, replenish the brake fluid in the reservoir as necessary. Make sure that there is always some fluid visible in the reservoir.
• Close the air bleeder valve, and disconnect the hose. Fill the reservoir with brake fluid to the top of the inspection window.
Air bleeder valve: 7.5 N ■ m (0.75 kg-m, 5.5 Ib-ft)
A CAUTION
Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials, etc.
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PERIODIC MAINTENA NCE 2-14
REAR BRAKE PEDAL HEIGHT
• Loosen the lock nut
• Adjust the brake pedal height by turning the adjuster
to locate the pedal 50 mm (2.0 in) above the top face of the footrest.
REAR BRAKE ADJUSTING
• Adjust the free travel to 20-30 mm (0.8-1.2 in) by turning the adjusting nut
REAR BRAKE SHOE WEAR
This motorcycle is equipped with brake lining wear limit indicator on the rear brake.
To check brake lining wear, perform the following steps.
• Make sure that the rear brake is properly adjusted.
• Depress the rear brake pedal. Make sure that the index mark is within the range embossed on the brake panel.
• If the index mark goes beyond the range, the brake shoe assembly should be replaced with a new set of shoes.
The extension line of the index mark is w ithin the range.
BRAKE LIGHT SWITCH
Adjust the rear brake light switch so that the brake light will come on just before pressure is felt when the brake pedal is depressed.
The extension line of the index mark is out of the ranae.
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2-15 PERIODIC MAINTENANCE
TIRE
Inspect every 5 000 km (3 000 miles, 15 months).
TIRE TREAD CONDITION
Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of tire tread reaches the following specification.
Tire tread depth limit (front): 1.6 mm (0.06 in)
(rear) : 2.0 mm (0.08 in)
09900-20805: Tire depth gauge
TIRE PRESSURE
If the tire pressure is too high or too low, steering will be adversely affected and tire wear increased. Therefore, maintain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows.
COLD INFLA TION
TIRE PRESSURE
FRONT
REAR
SOLO RIDING DUAL RIDING kPa kg/cm
2 psi kPa kg/cm
2 psi
175 1.75
25 175 1.75
25
200
2.00
29
225
2.25
33
CAUTION
The standard tire fitted on this motorcycle is a
110/90-16 59P for the front and a 130/90-15M/C 66P for the rear. The use of tires other than those specified may cause instability. It is highly recommended to use the specified tires.
STEERING
Inspect initially at 1 000 km (600 miles, 3 months) and every 10 000 km (6 000 miles, 30 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 front fork. Support the motorcycle so that the front wheel is off the ground. With the wheel facing straight ahead, grasp the lower fork tubes near the axle and pull forward. If play is found, readjust the steering. (See p. 5-27.)
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PERIODIC MAINTENA NCE 2-16
FRONT FORK
Inspect every 10 000 km (6 000 miles, 30 months).
Inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defective parts, if necessary.
REAR SUSPENSION
Inspect every 10 000 km (6 000 miles, 30 months).
Inspect the rear shock absorber for oil leakage and damage.
Replace any defective parts, if necessary.
CHASSIS BOLTS AND NUTS
Tighten initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 miles, 15 months) thereafter.
Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-17 for the locations of the following nuts and bolts on the motorcycle.)
ITEM N-m kg-m Ib-ft
16 1.6 11.5
Handlebar clamp bolt
Handlebar holder nut
Steering stem head bolt
45
65
23
Front fork upper clamp bolt
Front fork lower clamp bolt
4.5
6.5
2.3
32.5
47.0
16.5
Front fork cap bolt
Front fork damper rod bolt
Front axle
Front axle pinch bolt
Front brake caliper mounting bolt
Front brake hos e union bolt
33
23
23
65
23
39
23
3.3
2.3
2.3
6.5
2.3
3.9
2.3
24.0
16.5
16.5
47.0
16.5
28.0
16.5
Front brake caliper air bleeder valve
Front brake master cylinder mounting bolt
Front brake disc bolt
Front brake pad mounting bolt
Front footrest bolt
Swingarm pivot nut
Rear axle nut
For E-03, -28, -33
For the ot hers
7.5
10
23
18
26
72
65
78
13
0.75
1.0
2.3
1.8
2.6
7.2
5.5
7.0
16.5
13.0
19.0
52.0
Rear torque link nut (front and rear)
Rear shock absorber mounting bolt or nut
6.5
7.8
1.3
47.0
56.5
9.5
Rear sprocket nut
Rear brake cam lever bolt
Spoke nipple
29
50
10
4.5
2.9
5.0
1.0
0.45
21.0
36.0
7.0
3.5
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2-17 PERIODIC MAINTENANCE
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PERIODIC MAINTENANCE 2-18
COMPRESSION PRESSURE CHECK
The compression pressure reading of the 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
1 000-1 400 kPa
10.0-14.0 kg/cm
2
142-199 psi
Limit
800 kPa 8 kg/cm
2
114 psi
Low compression pressure can indicate any of the following conditions:
* Excessively worn cylinder wall
* 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 valves are properly ad justed.
• Have the engine warmed-up before testing.
" Make sure that the battery is fully-charged.
Remove the related parts and test the compression pressure in the following manner.
• 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.
09915-64510: Compression gauge
09918-03810: Adaptor
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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 SPECIFICA TION
Above 30 kPa (0.3 kg/cm
2
, 4.3 psi)
Below 70 kPa (0.7 kg/cm
2
, 10.0 psi) at 3 000 r/min., Oil temp, at 60°C (140°F)
If the oil pressure is lower or higher than the specification, the following caus es may be considered.
LOW OIL PRESSURE
* Clogged oil filter
* Oil leakage from the oil passage
* Damaged O-ring
* Defective oil pump
* Combination of the above items
HIGH OIL PRESSURE
* Engine oil viscosity is too high
* Clogged oil passage
* Combination of the above items
OIL PRESSURE TEST PROCEDURE
Check the oil pressure in the following manner. o Install the oil pressure gauge in the position shown.
• Connect an electric tachometer.
• Warm up the engine as follows:
Summer 10 min. at 2 000 r/min.
Winter 20 min. at 2 000 r/min.
• After warm up, increase the engine speed to 3 000 r/min. and read the oil pressure gauge.
09915-74510: Oil pressure gauge
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ENGINE
i ----------------------------------------------- CONTENTS --------------------------------
ENGINE COMPONENTS REMOVABLE WITH THE ENGINE
IN PLACE .......................................................................................................
.... 3- 1
ENGINE REMOVAL AND REINSTALLATION .............................................
ENGINE REMOVAL ...................................................................................
ENGINE REINSTALLATION
ENGINE DISASSEMBLY
...................................................................
........................................................................
3- 2 .... 3-
2
3- 6 .... 3-
9
ENGINE COMPONENTS INSPECTION AND SERVICE ....................... .... 3-19
CRANKCASE BEARINGS .................................................................... __ 3-19
CLUTCH RELEASE CAMSHAFT ......................................................... __ 3-22
CYLINDER HEAD COVER ................................................................... .... 3-23
CYLINDER HEAD ............................................................................... .... 3-24
CAM CHAIN GUIDE AND CAM CHAIN TENSIONER ....................... __ 3-32
CAMSHAFT ........................................................................................... __ 3-32
CAM CHAIN TENSION ADJUSTER ..................................................... __ 3-34
CYLINDER ............................................................................................. __ 3-34
PISTON AND PISTON PIN ................................................................... __ 3-34
CRANKSHAFT AND CONROD ............................................................ __ 3-37
BALANCER SHAFT AND BALANCER SHAFT DRIVEN GEAR
STARTER CLUTCH AND STARTER DRIVEN GEAR BEARING
3-39
3-40
GENERATOR STATOR AND PICK-UP COIL ....................................... __ 3-41
TRANSMISSION .................................................................................. __ 3-42
PRIMARY DRIVEN GEAR .................................................................... __ 3-44
CLUTCH ................................................................................................. __ 3-45
CLUTCH COVER ................................................................................... __ 3-46
OIL FILTER ............................................................................................ .... 3-46
OIL SUMP FILTER ................................................................................. .... 3-47
ENGINE REASSEMBLY ........................................................................... .... 3-48
CRANKSHAFT ...................................................................................... .... 3-48
BALANCER SHAFT .............................................................................. .... 3-48
TRANSMISSION .................................................................................. .... 3-48
GEARSHIFT CAM AND GEARSHIFT FORKS ..................................... .... 3-49
CRANKCASE ....................................................................................... .... 3-50
GENERATOR ROTOR ........................................................................ __ 3-52
DRIVESHAFT RETAINER ................................................................... __ 3-52
PRIMARY DRIVE GEAR ....................................................................... .... 3-52
BALANCER SHAFT BOLT ................................................................... .... 3-53
GEARSHIFT CAM DRIVEN GEAR ....................................................... .... 3-53
OIL PUMP .............................................................................................. .... 3-54
CLUTCH ................................................................................................. .... 3-55
CLUTCH COVER ................................................................................... __ 3-57
STARTER IDLE GEAR .......................................................................... __ 3-57
GENERATOR COVER .......................................................................... __ 3-57
NEUTRAL SWITCH ............................................................................... __ 3-58
ENGINE SPROCKET SPACER ............................................................ __ 3-58
STARTER MOTOR ................................................................................ .... 3-58
PISTON AND PISTON RING ................................................................ .... 3-59
CYLINDER ............................................................................................. .... 3-60
CYLINDER HEAD ............................................................................... .... 3-61
CAMSHAFT ........................................................................................... __ 3-62
CAM CHAIN TENSION ADJUSTER ..................................................... __ 3-63
CYLINDER HEAD COVER ................................................................... .... 3-64
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3-1 ENGINE
ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN
PLACE
The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to the pages listed in each section for removal and reinstallation instructions.
ENGINE CENTER
See page
Exhaust pipe and muffler ........... 3-2 and -8
Carburetor ............................... 3-4 and -7
Cam chain tension adjuster ... 3-9 and -63
Cylinder head cover ................... 3-9 and -64
Camshaft .................................3-10 and -62
Cylinder head .......................... 3-10 and -61
Cylinder .....................................3-10 and -60
Piston .....................................3-11 and -59
Starter motor ..............................3-11 and -58
Oil sump filter ........................... 3-47
ENGINE LEFT SIDE
See page
Gearshift link arm .......................3-2
Engine sprocket cover ................3-3
Engine sprocket ........................3-3 and -7
Generat or cover ........................ 3-12 and -57
Generat or rotor........................... 3-16 and -52
Starter idle gear ......................... 3-16 and -57
Generat or stator ........................3-41
Pick-up coil ................................3-41
Neut ral switch ........................... 3-11 and -58
ENGINE RIGHT SIDE
See page
Oil filter ...................................... 3-46
Clutch cover ............................... 3-12 and -57
Clutch ...................................... 3-12 and -55
Oil pump .................................... 3-14 and -54
Gearshift shaft ............................ 3-14 and -54
Primary drive gear ..................... 3-15 and -52
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ENGINE REMOVAL AND
REINSTALLATION
ENGINE REMOVAL
• Remove the front seat. (See p. 5-1.)
• Remove the fuel tank. (See p. 4-1.)
• Remove the right frame cover. (See p. 5-1.)
• Disconnect the battery lead wire.
• Drain the engine oil. (See p. 2-9.)
• Remove the right footrest bracket.
• Remove the exhaust pipe bolts.
• Remove the exhaust pipe by removing the bolt
• Remove the muffler mounting bolt
ENGINE 3-2
• Remove the gearshift link arm.
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3-3 ENGINE
• Remove the engine sprocket cover.
• Flatten the lock washer.
• Remove the engine sprocket nut and washer.
NOTE:
When loosening the engine sprocket nut, temporarily install the right footrest bracket and depress the brake pedal.
• Remove the engine sprocket.
NOTE:
If it is difficult to remove the engine sprocket, loosen the rear axle nut and chain adjuster nuts to provide additional chain slack.
• Remove the clutch release arm .
• Loosen the clutch cable adjuster lock nut and remove the clutch cable.
• Remove the left and right cylinder head cover caps.
• Disconnect the spark plug cap.
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• Remove the starter plunger .
• Loosen the carburetor clamp screws.
• Remove the carburetor.
¿WARNING
Gasoline is very explosive. Extreme care must be taken.
• Disconnect the engine ground wire.
• Disconnect the crankcase breather hose
• Disconnect the starter motor lead wire.
• Disconnect the side-stand switch coupler
• Disconnect the generator couplers
• Disconnect the neutral switch coupler
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ENGINE 3-4
3-5 ENGINE
• Support the motorcycle with a jack or wooden block.
• Remove the engine mounting bolts and nuts
• Remove the frame down tube mounting bolts and nuts
• Remove the lower engine mounting bolt and nut
• Remove the upper engine mounting bolt and nut
NOTE:
When removing the upper mounting bolt, support the engine with a jack.
• Remove the left and right swingarm pivot end caps.
• Remove the swingarm pivot nut and washer.
• Partially remove the swingarm pivot shaft so that the engine can be removed.
NOTE:
Be careful not to draw out the pivot shaft.
• Gradually lower the engine.
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ENGINE 3-6
ENGINE REINSTALLATION
Reinstall the engine in the reverse order of engine removal.
• Install the engine mounting bolts and nuts as shown in the following illustration.
• Tighten the engine mounting nuts to the specified torque.
NOTE:
The engine mounting nuts are self-locking. Once the nuts have been removed, they are no longer of any use.
ITEM N-m
41
41
41 kg-m Ib-ft
4.1
29.5
4.1
29.5
4.1
29.5
• Tighten the swingarm pivot nut to the specified torque.
Swingarm pivot nut: 72 N-m (7.2 kg-m, 52.0 Ib-ft)
BOLT LENGTH
50 mm (2.0 in)
67 mm (2.6 in)
100 mm (3.9 in)
• Tighten the frame down tube mounting bolts and nuts to the specified torque.
Frame down tube mounting bolt/nut: 23 N-m
(2.3 kg-m, 16.5 Ib-ft)
NOTE;
Apply a small quantity of THREAD LOCK "1303" to the threads of bolts.
99000-32030: THREAD LOCK SUPER "1303"
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3-7 ENGINE
• Tighten the engine ground wire and the clamp by crankcase bolt as shown.
• Clamp the neutral switch lead wire and side-stand switch lead wire
• Position the carburetor clamps as shown in the illustration.
• Install the clutch release arm as shown In the illustration.
NOTE:
Align the release arm slit surface with the notch mark on the release camshaft.
• Loosen the rear axle nut and drive chain adjuster nuts.
• Install the engine sprocket as shown.
• Install the drive chain.
• Tighten the engine sprocket nut torque.
to the specified
Engine sprocket nut: 90 N-m (9.0 kg-m, 65.0 Ib-ft)
NOTE:
When tightening the engine sprocket nut, depress the rear brake pedal.
• Bend the lock washer securely.
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• Tighten the exhaust pipe bolts and muffler mounting bolt to the specified torque.
Exhaust pipe bolt: 14 N-m (1.4 kg-m, 10.0 Ib-ft)
Muffler mounting bolt: 29 N-m (2.9 kg-m, 21.0 Ib-ft)
CAUTION
Check the wire, cable and hose routing.
(See pp. 7-11 to -18.)
ENGINE 3-8
• Install the right footrest and tighten its mounting bolts to the specified torque.
Front footrest bolt: 26 N-m (2.6 kg-m, 19.0 Ib-ft)
• After remounting the engine, the following adjustments are necessary.
* Engine idling speed ................................ See p. 2-7.
* Throttle cable play .................................. See p. 2-8.
* Starter plunger cable play ..................... See p. 2-9.
* Clutch lever play ................................... See p. 2-9.
* Drive chain slack .................................. See p. 2-11.
* Rear brake pedal height and free travel ............................................. See p. 2-14.
• Pour 1 700 ml (1.8/1.5 US/Imp qt) of SAE 10W/40 en gine oil, graded SF or SG, into the engine after overhaul ing it. Start up the engine and allow it run for several minutes at idle speed. Stop the engine, wait a few min utes and check the oil level. If the level is below the "L" line, add oil until the level reaches the "F" line. (See pp.
2-9 and -10.)
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3-9 ENGINE
ENGINE DISASSEMBLY
The procedure for engine disassembly is sequentially explained in the following steps.
• Remove the valve inspection caps
• Remove the spark plug.
• Remove the valve timing inspection plug and generator cover cap.
• Rotate the crankshaft and align the "T" line
on the generator rotor with the mark on the generator cover.
• Remove the cylinder head cover
NOTE:
If the cylinder head cover does not come off, lightly tap on the finless portion of it with a plastic mallet to make the gasketed joint loose.
• Remove the rubber cap and then turn the slotted end of cam chain tension adjuster with the flat-head screwdriver in the clockwise direction and lock the push rod.
• Remove the cam chain tension adjuster by removing the mounting bolts.
• Remove the camshaft end cap
• Flatten the lock washer and remove the camshaft sprocket bolts.
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• Remove the camshaft and camshaft sprocket .
CAUTION
Do not drop the cam chain into the crankcase.
• Remove the C-ring
CAUTION
Do not drop the C-ring into the crankcase.
• Remove the cylinder head nuts diagonally.
• Remove the cylinder head by removing the cylinder head nuts
NOTE:
If the cylinder head does not come off, lightly tap on the finless portion of it with a plastic mallet.
• Remove the cylinder head gasket and dowel pins.
• Remove the cam chain guide
• Remove the cylinder by removing the nuts.
NOTE:
If the cylinder does not come off, lightly tap on the Unless portion of it with a plastic mallet to make the gasketed joint loose.
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ENGINE 3-10
3-11 ENGINE
• Remove the cylinder gasket and dowel pins.
• Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into the crankcase.
Then, remove the piston pin circlip with a long-nose pliers.
• Remove the piston pin using the special tool.
09910-34510: Piston pin puller
• Remove the piston.
• Remove the starter motor
• Flatten the lock portion of the oil seal retainer
• Remove the oil seal retainer .
• Remove the spacer
• Remove the neutral switch
• Remove the neutral switch contact , spring and Oring
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• Remove the generator cover.
• Remove the gasket and dowel pins.
• Remove the clutch cover.
• Remove the gasket and dowel pins.
• While holding the generator rotor using the special tool, remove the clutch spring mounting bolts in a crisscross pattern, and remove the clutch springs and clutch pressure plate
09930-44913: Rotor holder
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ENGINE 3-12
3-13 ENGINE
• Remove the washer , bearing , clutch push piece
and clutch push rod
• Remove the clutch drive and driven plates.
• Remove the spring washer and washer seat
• Flatten the lock washer of the clutch sleeve hub nut.
• Remove the clutch sleeve hub nut using the special tool.
09920-53740: Clutch sleeve hub holder
• Remove the clutch sleeve hub
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• Remove the thrust washer and primary driven gear assembly
• Remove the spacer and thrust washer
• Remove the círclíp and oil pump driven gear
• Remove the pin and washer .
• Remove the oil pump
A CAUTION
Do not attempt to disassemble the oil pump assembly.
• Remove the gearshift shaft
• Remove the pawl lifter and cam guide by removing the screws.
• Remove the gearshift cam driven gear
NOTE:
When removing the cam driven gear , do not lose the pawls , pins and springs .
• Remove the gearshift shaft stopper
ENGINE 3-14
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3-15 ENGINE
• While holding the generator rotor using the special tool, remove the balancer shaft bolt
09930-44913: Rotor holder
• Remove the cam chain
• Remove the primary drive gear nut using the special tool.
09930-44913: Rotor holder
A CAUTION
The primary drive gear nut has left-hand threads.
• Remove the spring washer
• Remove the primary drive gear
• Remove the keys
• Remove the cam chain sprocket
• Remove the circlip and washer
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• Remove the shaft and starter idle gear
• Remove the generator rotor nut using the special tool.
09930-44913: Rotor holder
• Remove the generator rotor using the special tool.
09930-34960: Rotor remover
• Remove the generator rotor key
• Remove the starter driven gear
• Remove the bearing and washer
ENGINE 3-16
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3-17 ENGINE
• Remove the gearshift cam stopper.
• Remove the crankcase bolts.
• Separate the left and right crankcases using the special tool.
09920-13120: Crankcase separator
NOTE:
* Fit the crankcase separator, so that the tool arms are in parallel with the side of crankcase.
* The crankshaft and transmission components should remain in the left crankcase half.
* When separating the crankcase, tap the end of the countershaft with a plastic mallet.
* Remove the O-ring
• Remove the shim , washer and balancer shaft driven gear
• Remove the washer
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• Remove the gearshift cam stopper spring
• Remove the gearshift fork shafts and gearshift forks
• Remove the gearshift cam
• Remove the transmission.
• Remove the balancer shaft
• Remove the balancer shaft drive gear
• Remove the crankshaft using the special tool.
09920-13120: Crankcase separator
ENGINE 3-18
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3-19 ENGINE
ENGINE COMPONENTS
INSPECTION AND SERVICE
CRANKCASE BEARINGS
BEARING INSPECTION
While the bearing is in the crankcase, rotate its inner race and check to see that it turns smoothly. If it does not turn quietly and smoothly, or if there are signs of any abnormalities, the bearing is defective and must be replaced as follows.
BEARING REMOVAL
• Remove the bearing retainers
NOTE:
Remove the driveshaft bearing retainer along with the driveshaft bearing
• Remove the oil seals
using the special tool.
09913-50121: Oil seal remover
CAUTION
The removed oil seals should be replaced with new ones.
Remove the bearings.
CAUTION
The removed bearings should be replaced with new ones.
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• Remove the oil seal using the special tool.
09913-75510: Bearing remover/installer
A CAUTION
The removed oil seal should be replaced with a new one.
BEARING INSTALLATION
• Install the bearings using the special tools.
09913-75510: Bearing remover/installer (For )
09913-75520: Bearing remover/installer (For , )
09913-75830: Bearing remover/installer (For )
09913-84510: Bearing remover/installer (For )
09913-85210: Bearing remover/installer (For )
• Install the oil seal special tool.
into the left crankcase using the
09913-85210: Bearing remover/installer
• Apply grease to the oil seal lip.
99000-25010: SUZUK I SUPE R GREASE "A"
• Place the washer so that the convex of it faces towards the oil seal.
ENGINE 3-20
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3-21 ENGINE
• Install the left crankcase bearing using the special tool and suitable attachment (used beanng e.g.).
09913-75510: Bearing remover/installer
• Install the washer
• Install the left drlveshaft bearing with the bearing retainer
• Install the bearing retainers
NOTE:
Apply a small quantity of THREAD LOCK "1342" to the bearing retainer screws.
99000-32050: THREAD LOCK "1342"
• Apply grease to the oil seal lip
99000-
25010: SUZUKI SUPER GREASE "A"
• Install the driveshaft oil seals as shown.
CAUTION
When installing the oil seal , Do not block the oil passage.
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CLUTCH RELEASE CAMSHAFT
REMOVAL
• Remove the oil seal retainer and clutch cable guide
• Remove the oil seal
• Remove the clutch release cam shaft
REASSEMBLY
• Apply engine oil to the clutch release camshaft as shown in the illustration.
• Install the clutch release camshaft , washer and oil seal
ENGINE 3-22
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3-23 ENGINE
CYLINDER HEAD COVER
CAUTION
Identify the position of each removed part. Organize the parts in their re spective groups (i.e., intake or exhaust) so that they can be installed in their original locations.
DISASSEMBLY
• Remove the rocker arm shaft bolts
• Remove the rocker arm shafts
• Remove the rocker arms and wave washers
CYLINDER HEAD COVER DISTORTION
After removing the sealant (S UZUK I B OND "1215") from the mating surface of the cylinder head cover, place the cylinder head cover on a surface plate and check for distor tion with a thickness gauge. Check points are shown in Fig.
09900-20803: Thickne ss gauge
Service Limit: 0.05 mm (0.002 in)
If the distortion exceeds the limit, replace the cylinder head cover.
ROCKER ARM SHAFT O.D.
Measure the diameter of the rocker arm shafts.
09900-20205: Micrometer (0-25 mm)
Standard (IN. & EX.):
11.966-11.984 mm (0.4711-0.4718 in)
ROCKER ARM I.D.
Measure the inside diameter of the rocker arm and check the wear of the camshaft contacting surface.
09900-20605: Dial calipers
Standard (IN. & EX.):
12.000-12.018 mm (0.4724-0.4731 in)
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REASSEMBLY
Reassemble the cylinder head cover in the reverse order of disassembly. Pay attention to the following points: •
Apply engine oil to the rocker arm shafts.
• Install the rocker arms shafts
, wave washers and
[ A CAUTION]
Use the new O-rings to prevent oil leakage.
• Tighten the rocker arm shaft bolts to the specified torque.
Rocker arm shaft bolt: 10 Nm (1.0 kg-m, 7.0 Ib-ft)
CYLINDER HEAD
I A CAUTION |
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.
DISASSEMBLY
• Remove the cam chain tensioner
• Remove the intake pipe
ENGINE 3-24
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3-25 ENGINE
• Compress the valve spring using the special tools.
09916-14510: Valve lifter 09916-14910:
Valve lifter attachment
• Remove the valve cotters from the valve stem.
09916-84511: Tweezers
• Remove the valve spring retainer and valve spring
• Remove the valve from the combustion chamber side.
• Remove the valve stem seal
• Remove the valve spring seat
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CYLINDER HEAD DISTORTION
Decarbon the combustion chamber. Check the gasket surfac e of the cylinder head for distortion using a straightedge and thickness gauge. Take clearance readings at several places.
If readings exceed the service limit, replace the cylinder head.
09900-20803: Thickne ss gauge
Service Limit: 0.05 mm (0.002 in)
VALVE FACE W EAR
The t hickness of the valve face decreases as the face wears.
Visually inspect each valve face for wear and re place any valve with an abnormally worn face. Measure t he valve face thickness , if it is out of specification, replace the valve with a new one.
09900-20101: Vernier calipers
Service Limit: 0.5 mm (0.02 in)
VALVE STEM RUNOUT
Support the valve using V-blocks, as shown, and measure its runout with the dial gauge. If the runout exceeds the limit, replace the valve.
09900-20606: Dial gauge (1/100 mm)
09900-20701: Magnetic stand 09900-
21304: V-block (100 mm)
Service Limit: 0.05 mm (0.002 in)
VALVE HEAD RADIAL RUNOUT
Place the dial gauge at a right angle to the valve head face and measure the valve head radial runout.
If it meas ures more than the service limit, replace the valve.
09900-20606: Dial gauge (1/100 mm)
09900-20701: Magnetic stand 09900-21304:
V-block (100 mm)
Service Limit: 0.03 mm (0.001 in)
VALVE STEM DEFLECTION
Lift the valve about 10 mm (0.39 in) from the valve seat.
Measure the valve stem deflection in two directions, " X" and
"Y", perpendicular to each other. Position the dial gauge as shown. If the deflection exceeds the service limit, then determine whether the valve or the guide should be replaced with a new one.
09900-20606: Dial gauge (1/100 mm) 09900-
20701: Magnetic stand
Service Limit
Intake and exhaust valve s: 0.35 mm (0.014 in)
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ENGINE 3-26
3-27 ENGINE
VALVE STEM WEAR
Measure the valve stem O.D. using the micrometer. If it is out of s pecification, replac e the valve with a new one. If the valve stem O.D. is within specification but the valve stem deflection is not, replace the valve guide. A fter replacing the valve or valve guide, re-check the deflection.
09900-20205: Micrometer (0-25 mm)
Standard
Valve stem O.D.
IN.: 5.460-5.475 mm (0.2150-0.2156 in)
EX.: 5.445-5.460 mm (0.2144-0.2150 in)
NOTE:
If valve guides have to be replaced, refer to the valve guide servicing steps below.
VALVE GUIDE SERVICE
* Remove the valve guide using the special tool.
09916-44910: Valve guide remover/installer
NOTE:
* Discard the removed valve guide subassemblies.
* Only oversized valve guides are available as replacement parts.
• Re-finish the valve guide holes in the cylinder head using the special tools.
09916-34561: Valve guide reamer (11.3 mm)
09916-34542: Handle
NOTE:
Insert the reamer from the combustion chamber side and always turn the reamer handle clockwise.
• Install a ring onto each valve guide.
• Oil the stem hole of each valve guide and drive the guide into the guide hole using the special tool.
09916-44910: Valve guide remover/installer
A CAUTION
Be sure to use a new valve guide ring and valve guide.
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• After installing the valve guides, re-finish their guiding bores using the special tools. Be sure to clean and oil the guides after reaming.
09916-34550: Valve guide reamer (5.5 mm)
09916-34542: Handle
VALVE SEAT WIDTH
• Coat the valve seat uniformly with Prussian blue. Install the valve and attach a valve lapper onto it. Tap the coated seat with the valve face in a rotating manner, in order to obtain a clear impression of the seating contact.
• The ring-like dye impression left on the valve face must be continuous without any breaks. In addition, the width of the dye ring, which is the valve seat width, must be within the following specification:
Standard
Valve seat width : 0.9-1.1 mm (0.035-0.043 in)
If the valve seat is out of specification, re-cut the seat.
VALVE SEAT SERVICE
The valve seats for both intake and exhaust valves are machined to two different angles. (The seat contact surface is cut 45°.)
45°
15°
INTAKE SIDE
N-122
N-121
45°
15°
EXHAUST SIDE
N-122
N-121
09916-21111: Valve seat cutter set
09916-20610: Valve seat cutter (N-121)
09916-20620: Valve seat cutter (N-122)
09916-24450: Solid pilot (N-100-5.52)
NOTE:
The valve seat contact area must be inspected after each cut.
ENGINE 3-28
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3-29 ENGINE
• When installing the solid pilot , rotate it slightly. Seat the pilot snugly. Install the 45° cutter, attachment and
T-handle.
• Using the 45° cutter, descale and clean up the seat. Rotate the cutter one or two turns.
• Measure the valve seat width after every cut. If the valve seat is pitted or burned, use the 45° cutter to condition the seat same more.
NOTE:
Cut only the minimum amount necessary from the seat to prevent the possibility of the valve stem becoming too close to the rocker arm for correct valve contact angle.
If the contact area is too high on the valve, or If it is too wide, use the 15° cutter to lower and narrow the contact area.
If the contact area is too low or too narrow, use the 45° cutter to raise and widen the contact area.
• After the desired seat position and width is achieved, use the 45° cutter very lightly to clean up any burrs caused by the previous cutting operations.
CAUTION
DO NOT use lapping compound after the final cut is made. The finished valve seat should have a velvety smooth finish and not a highly polished or shiny finish. This will provide a soft surface for the final seating of the valve which will occur during the first few seconds of engine operation.
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.
WARNING
Always use extreme caution when handling gasoline.
NOTE:
After servicing the valve seats, be sure to check the valve clearance after the cylinder has been reinstalled. (See pp.
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Contact area too high and too wide on face of valve
2-4 to -6.)
Contact area too low and too narrow on face of valve
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VALVE SPRINGS
Check the valve springs for proper strength by measuring their free length and also the force required to compress them. If the spring length is less than the service limit or if the force required to compress the spring does not fall within the specified range, replace the spring.
09900-20201: Vernier calipers
Service Limit
Valve spring free length (IN. & EX.): 40.1 mm (1.58 in)
Standard
Valve spring tension (IN. & EX.): 18.4-21.6 kg/35.0 mm
(40.56-47.62 lbs/1.38 in)
REASSEMBLY
Reassemble the cylinder head in the reverse order of disassembly. Pay attention to the following points: • Install each valve spring seat .
• Apply molybdenum oil solution to the valve stem seal , and press-fit the seal into position by hand.
A CAUTION
Do not reuse the valve stem seals.
ENGINE 3-30
35.0 mm
(1.38 in)
18.4-21.6 kg
(40.56-47.62 lbs)
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3-31 ENGINE
• Apply molybdenum oil solution to the valve stems.
CAUTION
When inserting each valve, take care not to damage the lip of the stem seal.
• Install the valve springs with the smaller pitch facing the cylinder head.
• Install the valve spring retainer , press down the spring using the valve lifter and then install the cotter halves onto the valve stem end. Then, release the valve lifter to allow the cotter to wedge between the retainer and the valve stem. Be sure that the rounded lip of the cotter fits snugly into the groove in the stem end.
09916-14510: Valve lifter 09916-14910:
Valve lifter attachment 09916-84511:
Tweezers
CAUTION
Be sure to install all of the parts in their original positions.
INTAKE PIPE
• When installing the intake pipe, apply grease to the CDring.
99000-25010: SUZUKI SUPER GREASE "A"
CAUTION
Use the new O-ring to prevent sucking air from the joint.
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Tow ards
Head
NOTE:
Make sure that the "UP" mark comes upward.
CAM CHAIN GUIDE AND CAM CHAIN
TENSIONER
Check the cam chain guide and cam chain tensioner for wear and damage. If it is found to be damaged, replace it with a new one.
CAMSHAFT
CAMSHAFT INSPECTION
If the engine produces abnormal noises, vibration or lacks power, a camshaft may be distorted or worn to the service limit. The camshaft runout should be checked. Also, check the cams and journals for wear or damage.
CAM WEAR
Worn-down cams are often the cause of mistimed valve operation resulting in reduced power output. Measure the cam height using the micrometer. Replace a camshaft if the cams are worn to the service limit.
09900-20202: Micrometer (25-50 mm)
Service Limit
Cam height (IN.) : 34.690 mm (1.3657 in)
(EX.) : 34.730 mm (1.3673 in)
CAMSHAFT JOURNAL WEAR
Determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place. Measure the clearance using the plastigauge .
09900-22301: Plastigauge
09900-22302: Plastigauge
ENGINE 3-32
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3-33 ENGINE
NOTE:
Install the cylinder head cover to its original position.
Tighten the cylinder head cover bolts evenly and diagonally to the specified torque.
Cylinder head cover bolt: 10 N ■ m (1.0 kg-m, 7.0 Ib-ft)
NOTE:
Do not rotate the camshaft with the plastigauge in place.
Remove the cylinder head cover and measure the width of the compressed plastigauge using the envelope scale. This measurement should be taken at the widest part of the compressed plastigauge.
Service Limit
Camshaft-Journal oil clearance: 0.150 mm
(0.0059 in)
If t he camshaft journal oil clearance exceeds the limit, measure the inside diameter of the camshaft journal holder and outside diamet er of the camshaft journal. Replace the camshaft or the cylinder head depending upon which one exceeds the specific ation.
09900-22403: Small bore gauge
Standard
Camshaft journal holder I.D.
(Right side) : 25.012-25.025 mm (0.9847-0.9852 in)
(Left side) : 20.012-20.025 mm (0.7879-0.7884 in)
09900-20205: Micrometer (0-25 mm)
Standard
Camshaft journal O.D.
(Right side) : 24.959-24.980 mm (0.9826-0.9835 in)
(Left side) : 19.959-19.980 mm (0.7858-0.7866 in)
CAMSHAFT RUNOUT
Measure the runout using a dial gauge. Replace the cam shaft if the runout exceeds the limit.
09900-20606: Dial gauge (1/100 mm)
09900-20701: Magnetic stand 09900-21304:
V-block set (100 mm)
Service Limit
Camshaft runout: 0.10 mm (0.004 in)
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CAM CHAIN TENSION ADJUSTER
The cam chain tension adjuster is maintained at the proper tension by an automatically adjusted tensioner. Insert a flathead screwdriver into the slotted end of the cam chain tension adjuster and turn it clockwise to release the tension.
Remove the screwdriver to make sure that the push rod moves properly. If the push rod is stuck or the spring mechanism does not work, replace the cam chain tension adjuster assembly with a new one.
CYLINDER
DISTORTION
Check the gasket surface of the cylinder for distortion using a straightedge and thickness gauge. Take clearance readings at several places. If any reading exceeds the service limit, replace the cylinder.
09900-20803: Thickness gauge Service Limit: 0.05 mm (0.002 in)
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
09900-20508: Cylinder gauge set
Service Limit: 72.085 mm (2.8380 in) replace the cylinder.
PISTON AND PISTON PIN
DIAMETER
Measure the piston diameter using the micrometer at 15 mm (0.6 in) from the skirt end.
If the piston diameter is less than the service limit, replace the piston.
09900-20203: Micrometer (50-75 mm)
Service Limit: 71.880 mm (2.8299 in) Piston oversize: 0.5, 1.0 mm
PISTON-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 cylinder and the piston.
Service Limit: 0.120 mm (0.0047 in)
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ENGINE 3-34
3-35 ENGINE
PISTON RING-GROOVE CLEARANCE
Measure the side clearance of the 1st and 2nd rings using the thickness gauge If any of the clearances exceed the limit, replace both the piston and piston rings.
09900-20803: Thickness gauge 09900-
20205: Micrometer (0-25 mm)
Service Limit
Piston ring-groove clearance 1st: 0.180 mm
(0.0071 in)
2nd: 0.150 mm
(0.0059 in)
Standard
Piston ring groove width
1st: 1.01-1.03 mm
(0.040-0.041 in)
2nd: 1.21-1.23 mm
(0.047-0.048 in)
Oil: 2.51-2.53 mm
(0.099-0.100 in)
Standard
Piston ring thickness
1st: 0.975-0.990 mm
(0.0384-0.0390 in)
2nd: 1.170-1.190 mm
(0.0461-0.0469 in)
NOTE:
Remove any carbon from the piston crown and ring grooves using a soft-metal scraper.
PISTON RING FREE END GAP AND PISTON RING END
GAP
Measure the piston ring free end gap using a vernier cali pers.
Next, fit the piston ring squarely into the cylinder and measure the piston ring end gap using a thickness gauge. If the piston ring's end gap is out of specification, replace the piston ring.
09900-20101: Vernier calipers
Service Limit
Piston ring free end gap 1st: 7.6 mm (0.30 in)
2nd: 8.8 mm (0.35 in)
09900-20803: Thickness gauge
Service Limit
Piston ring end gap (1st and 2nd): 0.50 mm (0.020 in)
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OVERSIZE RINGS
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
1.0 mm: 100
Oversize oil ring
The following oversize oil ring is used. It bears the following Identification mark.
Oil ring 0.5 mm: Painted blue 1.0 mm: Painted yellow
Oversize side rail
Measure the outside diameter to identify the side.
PIN BORE
Measure the piston pin bore inside diameter using the caliper gauge and measure the piston pin outside diameter using the micrometer. If either is out of specification or the difference between these two measurements is more than the limits, replace both piston and piston pin.
09900-20605: Dial calipers 09900-
20205: Micrometer (0-25 mm)
Service Limit
Piston pin bore: 18.030 mm (0.7098 in)
Piston pin O.D.: 17.980 mm (0.7079 in)
ENGINE 3-36
0.5mmO.S
I.OmmO.S.
Oil ring spacer
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3-37 ENGINE
CRANKSHAFT AND CONROD
Crankshaft, RH
Conrod
Bearing
Crank pin
Crankshaft,
LH
CONROD SMALL END I.D.
Measure the conrod small end inside diameter using the dial calipers. If the conrod small end inside diameter exceeds the service limit, replace the conrod.
09900-20605: Dial calipers
Service Limit: 18.040 mm (0.7102 in)
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CONROD DEFLECTION AND CONROD BIG END SIDE
CLEARANCE
Wear on the big end of the conrod can be estimated by checking the movement of the small end of the rod. This method can also check the extent of wear on the parts of the conrod's big end.
09900-20701: Magnetic stand 09900-20606:
Dial gauge (1/100 mm) 09900-21304: Vblock set (100 mm)
Service Limit: 3.0 mm (0.12 in)
Push the big end of the conrod to one side and measure the side clearance using a thickness gauge.
09900-20803: Thickne ss gauge
Standard: 0.10-0.65 mm (0.004-0.026 in) Service
Limit: 1.0 mm (0.04 in)
If the service limit is exceeded, replace crankshaft assembly or bring the deflection and side clearance into specifica tion by replacing the worn parts, (e.g., conrod, big end bearing and crank pin)
CRANKSHAFT RUNOUT
Support the crankshaft with V-blocks as shown. Position the dial gauge, as shown, and rotate the crankshaft slowly to read the runout. Correct the runout or replace the crankshaft assembly if the runout is greater than the service limit.
09900-20701: Magnetic stand 09900-
20606: Dial gauge (1/100 mm) 09900-
21304: V-block set (100 mm)
Service Limit: 0.05 mm (0.002 in)
REASSEMBLY
• When rebuilding the crankshaft, the width between the webs should be within the standard range.
Standard width between webs : 60.0 + 0.1 mm
(2.362 ±0.004 in)
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ENGINE 3-38
3-39 ENGINE
BALANCER SHAFT AND BALANCER SHAFT DRIVEN GEAR
DISASSEMBLY
• Disassemble the balancer shaft as shown in the illustration.
Balancer shaft
Key
Balancer shaft driven
Spring (6 pcs.)
Pin (3 pcs.)
INSPECTION
Inspect the balancer shaft and balancer shaft driven gear for wear or damage. If any wear or damage is found, replace the defective part.
Measure the free length of each balancer spring using vernier calipers. If any spring is not within the service limit, replace all of the spring.
09900-20101: Vernier calipers
Service Limit: 10.0 mm (0.39 in)
REASSEMBLY
Reassemble the balancer shaft driven gear in the reverse order of disassembly. Pay attention to the following points:
• Make sure that the punch mark on the inner race is aligned with the punch mark on the balancer shaft driven gear.
: Pin
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STARTER CLUTCH AND STARTER DRIVEN GEAR BEARING
ENGINE 3-40
1
Starter driven gear
2 Starter clutch
3 Roller
4 Push piece
5
Spring
STARTER CLUTCH
Install the starter driven gear onto the starter clutch and turn the starter driven gear by hand (the gear turns in only one direction). The starter driven gear should t urn smoot hly. If excessive resistance is felt while turning the starter driven gear, inspect the starter clutch. Also, inspect the surface of the starter driven gear which cont acts the starter clutch, for wear or damage. If any wear or damage is found, replace th e defective part (-s).
STARTER DRIVEN GEAR BEARING
Install the starter driven gear bearing and gear onto the crankshaft and turn the starter driven gear by hand.
Inspect the starter driven gear bearing for smooth rotation and any abnormal noise. If the bearing does not turn smoothly or there is any abnormal noise, replace it.
DISASSEMBLY
• Remove the starter driven gear.
• Remove the roller , spring and push piece
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3-41 ENGINE
• Hold the generator rotor with the rotor holder and remove the starter clutch bolts.
09930-44913: Rotor holder
REASSEMBLY
• Locate the shim to the proper position.
• Apply a small quantity of THREAD LOCK SUPER "1303" to the starter clutch bolts and tighten them to the specified torque while holding the rot or holder.
99000-32030: THREAD LOCK SUPER "1303"
09930-44913: Rotor holder Starter clutch bolt: 18 N-m (1.8 kg-m, 13.0 Ib-ft)
GENERATOR STATOR AND PICK-UP
COIL
When replacing the generator stator or pick-up coil apply THREAD LOCK "1342" to the generator stator set bolts and pick-up coil set bolts and tighten them.
99000-32050: THREAD LOCK "1342"
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TRANSMISSION
DISASSEMBLY
• Disassemble the transmission gears as shown in the illustration.
ENGINE 3-42
1
1st driven gear
2
5th driven gear 3
3rd driven gear 4 4th driven gear 5 2nd driven gear 6
Driveshaft 7
Countershaft 8 5th drive gear 9 3rd drive gear 10 4th drive gear
11
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.
CAUTION ____________________________________________________________________
* Never reuse a circlip. After a circlip has been removed from a shaft, it should be dis carded and a new circlip must be installed.
* When installing a new circlip, do not expand the end gap larger than required to slip the circlip over the shaft.
* After installing a circlip, make sure that it is completely seated in its groove and securely fitted.
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3-43 ENGINE
When installing a new circlip, pay attention to the direction of the circlip. Fit the circlip to the side where the thrust is as shown in the illustration. The rounded side should be against the gear surface.
Thrust
Sharp edge
Washers and circlips thickness
1.2 mm (0.05 in) 1.0 mm
(0.04 in) 1.0 mm (0.04 in)
1.0 mm (0.04 in) 2.0 mm
(0.08 in) 0.5 mm (0.02 in)
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GEARSHIFT FORKS
Measure the gearshift fork clearance in the groove of its respective gear using the thickness gauge. The clearance for each of the two gears hift forks plays an import ant role in the smoothness and positiveness of the shifting action. Each fork has its prongs fitted into the annu lar groove provided in its gear. During operation there is sliding contact between the fork and gear and, when a shifting action is initiated, the fork pushes t he gear axially. If the clearanc e is too great, the meshed gears may slip apart.
If the clearance exceeds the specification, replace the fork, its respective gear or both.
09900-20803: Thickne ss gauge
Service Limit
Gearshift fork to groove clearance: 0.60 mm (0.024 in)
Standard
Gearshift fork groove width No.1, No.2 & No.3: 4.25-4.35 mm (0.167-0.171 in)
Standard
Shift fork thickness No.1, No.2 & No.3: 3.95-4.05 mm
(0.156-0.159 in)
PRIMARY DRIVEN GEAR
• Remove the stopper ring
• Remove the oil pump drive gear
If the internal damper wears, play is generated between gear and housing, causing abnormal noise. If the play is extreme, replace the primary driven gear assembly with a new one.
Primary driven gear
Damper
Clutch housing
ENGINE 3-44
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3-45 ENGINE
CLUTCH
CLUTCH DRIVE PLATES
Measure the thickness and claw width of the clutch drive plates using vernier calipers. If a clutch drive plate is not within the service limit, replace the clutch plates as a set.
09900-20101: Vernier calipers
Service Limit
Thickness (No.1): 2.62 mm (0.103 in)
(No.2): 3.15 mm (0.124 in) Claw width:
15.0 mm (0.590 in)
CLUTCH DRIVEN PLATES
Measure each clutch driven plates for distortion using the thickness gauge. If a clutch driven plate is not within the service limit, replace the clutch plates as a set.
09900-20803: Thickness gauge
Service Limit: 0.10 mm (0.004 in)
CLUTCH SPRING FREE LENGTH
Measure the free length of each clutch spring using vernier calipers. If any spring is not within the service limit, replace all of the spring.
09900-20101: Vernier calipers Service Limit: 40.9 mm (1.61 in)
CLUTCH RELEASE BEARING
Inspect the clutch release bearing for any abnormality, especially cracks. When removing the bearing from the clutch, decide whether it can be reused or if it should be replaced.
Smooth engagement and disengagement of the clutch depends on the condition of this bearing.
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CLUTCH COVER
• Remove the oil seal retainer
• Remove the oil seal using the special tool.
09913-50121: Oil seal remover
• Install the new oil seal using a suitable socket
• Install the oil seal retainer.
NOTE:
Apply a small quantity of THREAD LOCK "1342" to the oil seal retainer screws.
99000-32050: THREAD LOCK "1342"
OIL FILTER
• Remove the oil filter cap
• Remove the oil filter and install a new one.
NOTE:
Before installing the new oil filter and oil filter cap, make sure that the spring and new O-rings installed correctly.
are
• Install the oil filter cap.
ENGINE 3-46
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3-47 ENGINE
OIL SUMP FILTER
• Remove the oil sump filter cap
• Remove the oil sump filter
INSPECTION
Check the oil sump filter for any damage or clogs.
CLEANING
Clean the oil sump filter with a compressed air.
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ENGINE 3-48
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 crankcase, it is necessary to pull its left end into the left crankcase with the special tools.
09910-32812: Crankshaft installer
09910-32840: Attachment 09910-
20116: Conrod holder
CAUTION
Never install the crankshaft into the crankcase by striking it with a plastic hammer. Always use the special tool, otherwise crankshaft may be misaligned.
• Apply engine oil to the crankshaft bearings.
• Install the balancer shaft drive gear .
NOTE:
Make sure that the hole in the drive gear is aligned with the pin on the crankshaft.
BALANCER SHAFT
• Install the balancer shaft
TRANSMISSION
• Install the countershaft and driveshaft assemblies.
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3-49 ENGINE
• Install the washer , balancer shaft driven gear washer and shim onto the balancer shaft.
NOTE:
Make sure that the key is aligned with the keyway.
• Align the punch mark on the balancer shaft driven gear with the punch mark on the balancer shaft drive gear
GEARSHIFT CAM AND GEARSHIFT
FORKS
• Align the pin groove of gearshift cam stopper plate with the pin on the gearshift cam.
• Install the gearshift forks to their respective gears.
• Install the gearshift cam stopper
• Install the gearshift cam into the crankcase.
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• Install the gearshift fork shafts
NOTE:
Position the gearshift cam as shown in Fig. so that the gearshift fork shafts can be installed easily.
• Install the the gearshift cam stopper spring
CRANKCASE
• Wipe both crankcase mating surfaces with a cleaning solvent.
• Apply SUZUKI BOND "1215" uniformly to the mating surface of the right crankcase and assemble the cases within a few minutes.
99000-31110: SUZUKI BOND "1215"
ENGINE 3-50
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3-51 ENGINE
• Install the dowel pins into the left half of the crankcase.
• Install the O-ring
A CAUTION
Use a new O-ring
• Apply engine oil to the conrod big end and transmission gears.
• Tighten the crankcase bolts to the specified torque.
Crankcase bolt: 11 N-m (1.1 kg-m, 8,0 Ib-ft)
NOTE:
Install the clamp to the bolt .
NOTE:
* After the crankcase bolts have been tightened, make sure that the crankshaft, countershaft and driveshaft rotate smoothly.
* If these shafts do not rotate smoothly, try to free it by tapping with a plastic hammer.
• Install the the gearshift cam stopper.
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GENERATOR ROTOR
• Remove any grease from the tapered portion of the generator rotor and crankshaft.
• Install the washer so that the convex side of it faces the crankcase bearing.
• Install the bearing
• Install the starter driven gear
• Install the generator rotor key onto the crankshaft.
• Install the generator rotor securely.
• Apply a small quantity of THREAD LOCK "1303" to the generator rotor nut.
99000-32030: THREAD LOCK SUPER "1303"
• Tighten the generator rotor nut to the specified torque using the special tool.
09930-44913: Rotor holder
Generator rotor nut: 160 N ■ m (16.0 kg-m, 115.5 Ib-ft)
DRIVESHAFT RETAINER
• Install the washer and circlip to the driveshaft.
CAUTION Use a new circlip
PRIMARY DRIVE GEAR
• Install the cam chain sprocket , cam chain sprocket key and primary drive gear key
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3-53 ENGINE
• Install the primary drive gear , wave washer and primary drive gear nut
NOTE:
This nut has left hand threads.
• Tighten the primary drive gear nut to the specified torque using the special tool.
09930-44913: Rotor holder
Primary drive gear nut :
100 N-m (10.0 kg-m, 72.5 Ib-ft)
BALANCER SHAFT BOLT
• Apply a small quantity of THREAD LOCK "1342" to the balancer shaft bolt.
99000-32050: THREAD LOCK "1342"
• Tighten the balancer shaft bolt to the specified torque using the special tool.
09930-44913: Rotor holder Balancer shaft bolt : 39 N-m (3.9 kg-m, 28.0 Ib-ft)
GEARSHIFT CAM DRIVEN GEAR
• Install each pawl into the gearshift cam driven gear.
Gearshift pawl
Pin
Spring driven gear
Gearshift cam
NOTE:
The large shoulder must face to the outside.
• Apply a small quantity of THREAD LOCK "1303" to the gearshift shaft stopper
99000-32030: THREAD LOCK SUPER "1303"
• Tighten the gearshift shaft stopper to the specified torque.
Gearshift cam stopper: 19 N-m (1.9 kg-m, 13.5 Ib-ft)
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• Install the gearshift cam driven gear assembly.
• Install the pawl lifter and cam guide
NOTE:
Apply a small quantity of THREAD LOCK "1342" to the threads of the screws.
99000-32050: THREAD LOCK "1342"
• Install the return spring
to the gearshift shaft as shown.
• Install the gearshift shaft.
NOTE:
Align the center teeth on the gearshift shaft with the center teeth on the gearshift cam driven gear.
OIL PUMP
• Apply engine oil to the sliding surfaces of the oil pump case, outer rotor, inner rotor and shaft, before mounting the oil pump.
• Apply a small quantity of THREAD LOCK "1342" to the oil pump mounting screws and tighten them.
99000-32050: THREAD LOCK "1342"
• Install the washer and pin
• Install the oil pump driven gear and circlip
ENGINE 3-54
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3-55 ENGINE
CLUTCH
Clutch pressure plate
Push piece
Clutch drive plate No.1 (T: 3.00)
Clutch driven plate
Clutch drive plate No.2 (T: 3.50)
Clutch push rod
Concaved w asher
Washer seat
Clutch sleeve hub
Clutch housing
Oil pump drive gear
• Install the washer and spacer onto the countershaft.
NOTE:
Apply engine oil to the inside and outside surfaces of the spacer.
• Install the primary driven gear assembly and thrust washer onto the countershaft.
NOTE:
When engaging the primary drive and driven gears, turn the primary driven gear assembly to the counterclockwise.
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• Install the clutch sleeve hub and lock washer.
• Install the clutch sleeve hub nut, and tighten it to the specified torque using the special tool.
09920-53740: Clutch sleeve hub holder
Clutch sleeve hub nut: 50 N-m (5.0 kg-m, 36.0 Ib-ft)
• Bend the lock washer securely.
• Install the washer seat and spring washer as shown.
• Install the clutch drive plate No.2
• Install the clutch drive plates No.1 and driven plates
one by one into the clutch sleeve hub.
• Install the clutch push rod
• Install the push piece , bearing and washer
• Install the clutch pressure plate , clutch springs and clutch spring mounting bolts.
• Hold the generator rotor using the special tool and tighten the clutch spring mounting bolts to the specified torque in a crisscross pattern.
09930-44913: Rotor holder
Clutch spring mounting bolt:
10N-m(1.0kg-m, 7.0 Ib-ft)
NOTE:
Make sure that the clutch pressure plate is installed correctly.
• Loosen the lock nut , and turn in the release screw to feel resistance.
• From that position, turn out the release screw turn, and tighten the lock nut by holding the release screw
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ENGINE 3-56
3-57 ENGINE
CLUTCH COVER
• Install the two dowel pins and new gasket
• Tighten the clutch cover bolts securely.
A CAUTION
Install the new gasket washer to the bolt .
STARTER IDLE GEAR
• Install the starter idle gear
A CAUTION
Apply engine oil to the starter idle gear
GENERATOR COVER
• Install the dowel pins and a new gasket
• Install the generator cover and tighten the bolts securely.
NOTE:
Install the wire harness clamp with the bolt
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NEUTRAL SWITCH
• Install the spring and neutral switch contact and new O-ring
• Install the neutral switch.
ENGINE SPROCKET SPACER
• Apply SUZUKI SUPER GREASE "A" to the O-ring of the engine sprocket spacer and the oil seal lip.
99000-25010: SUZUKI SUPER GREASE "A"
A CAUTION
Use a new O-ring
* Install the engine sprocket spacer onto the driveshaft.
NOTE:
* The oil hole on the spacer should be on the engine side.
* Be careful that the oil seal lip does not turn in.
• Install the oil seal retainer .
• Bend the tabs on the oil seal retainer to lock the bolts.
• Pass through the neutral switch lead wire inside of the guide
• Clamp the neutral switch lead wire and generator lead wire with the clamp
STARTER MOTOR
• Install the starter motor.
A CAUTION
Use a new O-ring.
NOTE:
Apply grease to the O-ring.
99000-25010: SUZUKI SUPER GREASE "A"
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3-59 ENGINE
PISTON AND PISTON RING
• First, install a spacer into the oil ring groove and then install the two side rails . The spacer and side rails do not have a specific top or bottom when they are new. When reassembling used parts, install them in their original place and direction.
A CAUTION
When installing the spacer, be careful not to allow its two ends to overlap in the piston ring groove.
INCORRECT
• Same way in which to distinguish the 1st and 2nd piston rings:
1. Their ring face shapes are different.
2. The 1st piston ring's face is chrome-plated.
3. The 2nd piston ring appears darker in color.
• The 1st and 2nd piston should be installed with their marks facing up.
• Position the piston ring gaps as shown.
NOTE:
Before inserting the piston into the cylinder, check that the gaps are properly positioned.
• 2nd ring
• Lower side rail
EX.
Upper side rail
• 1st ring
IN. • Spacer
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The following are reminders for piston installation:
• Before Installing the piston pin, apply molybdenum oil solution onto its surface.
• Apply engine oil to the big and small ends of the conrod.
• Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into crankcase. Install the piston pin circlip with long-nose pliers.
A CAUTION
Use a new piston pin circlip to prevent circlip failure.
• Install the piston with the arrow mark facing towards the exhaust side.
CYLINDER
Before installing the cylinder, apply engine oil to the sliding surface of the piston.
• Install the dowel pins into the crankcase and then Install the cylinder gasket
A CAUTION
Use a new gasket to prevent oil leakage.
• Make sure that the piston rings are properly positioned, and insert the piston into the cylinder.
NOTE:
When mounting the cylinder, keep the cam chain taut. The cam chain must not be caught between the cam chain drive sprocket and crankcase when crankshaft is rotated.
• Temporarily tighten the cylinder base nuts.
• Install the cam chain guide
ENGINE 3-60
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3-61 ENGINE
CYLINDER HEAD
• Install the dowel pins into the cylinder and then install the cylinder head gasket onto the cylinder.
A CAUTION
Use a new gasket to prevent gas leakage.
• Place the cylinder head onto the cylinder.
• Cylinder head nuts and washers must be installed correctly as shown.
Copper washer
Steel washer
• Tighten the cylinder head nuts (10-mm) to the specified torque in a crisscross pattern.
Cylinder head nut (10-mm): 38N-m
(3.8 kg-m, 27.5 Ib-ft)
• Tighten the cylinder base nuts (2) and cylinder head nuts
(6-mm) (D to the specified torque.
H Cylinder base nut ©: 10 N-m (1.0 kg-m, 7.0 Ib-ft)
Cylinder head nut (6-mm) ®: 10 N-m
(1.0 kg-m, 7.0 Ib-ft)
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CAMSHAFT
• Turn the crankshaft counterclockwise, and align the T line on the generator rotor with the mark on the generator cover while keeping the cam chain tight.
I A CAUTION]
If the crankshaft is turned without drawing the cam chain upward, the cam chain will catch between crankcase and cam chain drive sprocket.
NOTE:
Just before installing the camshaft into the cylinder head, apply molybdenum oil solution to the camshaft journals and cam faces. Also, apply engine oil to the camshaft journal holders.
• Install the C-ring into the ring groove of the cylinder head.
• Install the cam chain.
• Install the camshaft and camshaft sprocket
• Face the notch on the camshaft towards the intake side.
• Align the engraved line marks on the camshaft so it is parallel with mating surface of the cylinder head and cylinder head cover.
• Engage the cam chain on the camshaft sprocket with the locating pin hole at one o'clock position.
NOTE:
Do not rotate the crankshaft while installing the camshaft or cam chain.
• Install the lock washer so that it is covering the locating pin.
NOTE:
Apply a small quantity of THREAD LOCK SUPER "1303" to the threads of the camshaft sprocket bolts.
99000-32030: THREAD LOCK SUPER "1303"
• Tighten the camshaft sprocket bolts to the specified torque.
Camshaft sprocket bolt: 15 N-m (1.5 kg-m, 11.0 Ib-ft)
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ENGINE 3-62
3-63 ENGINE
• Bend the lock washer securely.
Camshaft
Pin
Bolt
Lock washer
Camshaft sprocket
• Install the camshaft end cap.
CAM CHAIN TENSION ADJUSTER
NOTE:
* Before installing the cam chain tension adjuster, lock the tension spring with a flat-head screwdriver.
* Before installing the cam chain tension adjuster, turn the crankshaft counterclockwise to remove any cam chain slack between the cam chain drive sprocket and camshaft sprocket.
* Install a new gasket and the cam chain tension adjuster onto the cylinder with the two bolts and tighten them to the specified torque.
Cam chain tension adjuster bolt:
7 N-m (0.7 kg-m, 5.0 Ib-ft)
• After installing the cam chain tension adjuster, turn the screwdriver counterclockwise. As the slot in the cam chain tension adjuster turns, the tension rod advances under the spring force and pushes the cam chain tension adjuster against the cam chain.
A CAUTION
After installing the cam chain tension adjuster, check the cam chain slack to make sure that the cam chain tension adjuster is working properly.
• Fit the rubber cap.
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CYLINDER HEAD COVER
• Pour motor oil in the oil pocket in the cylinder head.
NOTE:
Turn the crankshaft and check that all the moving parts
(e.g., cam follower, camshaft) work properly.
• Clean the mating surfaces of the cylinder head and head cover.
• Install the dowel pins.
• Apply SUZUKI BOND N0.1215 uniformly to the mating surface of the cylinder head cover and install it within a few minutes.
99000-31110: SUZUKI BOND N0.1215
• Tighten the cylinder head cover bolts to the specified torque.
Cylinder head cover bolt: 10 N ■ m (1.0 kg-m, 7.0 Ib-ft)
I A CAUTION |
Install the new gasket washer to the bolt
A CAUTION
Be sure to check the valve clearance. (See pp. 2-3 and -4.)
• Install the valve timing inspection caps.
CAUTION
Use new O-rings to prevent oil leakage.
ENGINE 3-64
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FUEL AND LUBRICATION SYSTEM
--------------------------------------------
CONTENTS
---------------------------------------------
FUEL TANK AND FUEL VALVE
................................................................
4- 1
REMOVAL
.................................................................................................
4- 1
INSPECTION
............................................................................................
4- 1
REMOUNTING
........................................................................................
4- 1
CARBURETOR
.............................................................................................
4- 2
SPECIFICATIONS
..................................................................................
4-2
I.D. NO. LOCATION
.................................................................................
4-2
CONSTRUCTION
.....................................................................................
4-3
REMOVAL
................................................................................................. 4-
4
DISASSEMBLY
......................................................................................... 4- 4
CLEANING
................................................................................................ 4-
8
INSPECTION AND ADJUSTMENT
........................................................
4-8
REASSEMBLY
......................................................................................... 4-
9
REMOUNTING
........................................................................................ 4-
9
LUBRICATION SYSTEM
.............................................................................
4-10
OIL PRESSURE
........................................................................................
4-10
OIL FILTER
...............................................................................................
4-10
OIL SUMP FILTER
...................................................................................
4-10
ENGINE LUBRICATION SYSTEM CHART
............................................
4-11
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4-1 FUEL AND
LUBRICATION SYSTEM
FUEL TANK AND FUEL VALVE
REMOVAL
A WARNING
Gasoline is very explosive. Extreme care must be taken.
• Remove the front seat. (See p. 5-1.)
• Remove the fuel tank mounting bolts.
• Turn the fuel valve to "ON" or "RES" position.
• Disconnect the fuel hose and vacuum hose
• Remove the fuel tank.
• Remove the fuel valve.
INSPECTION
FUEL VALVE
If the fuel filter is dirty with sediment or rust, fuel will not flow smoothly and loss in engine power may result. Clean the fuel filter with compressed air. Also check the fuel filter for cracks.
AWARNING
Gaskets and O-rings must be replaced with new ones to prevent fuel leakage.
REMOUNTING
• Remount the fuel tank and fuel valve in the reverse order of removal.
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FUEL AND LUBRICATION SYSTEM 4-2
CARBURETOR
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.)
Pilot air jet No. 1 (P.A.J.1)
Pilot air jet No.2 (P.A.J.2)
Throttle valve (Th.V.)
Pilot screw (PS.)
Throttle cable play
Starter plunger cable play
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.)
Pilot air jet No. 1 (P.A.J.1)
Pilot air jet No.2 (P.A.J.2)
Throttle valve (Th.V.)
Pilot screw (PS.)
Throttle cable play
Starter plunger cable play
I.D. NO. LOCATION
The carburetor has I.D. Number stamped on its body according to its specifications.
SPECIFICATION
E-01, 02, 04, 25, 34
MIKUNI BSR32SS
32 mm
E-17, 22, 24
13F2 13F0
1 300 ± 100 r/min.
13.0 ±0. 5 mm
#115
5C60-3rd
P-0
#17.5
#87.5
#140
#110
turns out
2-4 mm (0.08-0.16 in)
0.5-1. 0 mm (0.02-0. 04 in)
turns out
SPECIFICA TION
E-33 E-03, 28
MIKUNI BSR32SS
32 mm
13F3
1 300 ± 50 r/min.
13.0 ±0. 5 mm
13F4
5C65
#87.5
#120
#110
PRE-SE T
2-4 mm (0.08-0.16 in)
0.5-1. 0 mm (0.02-0. 04 in)
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4-3 FUEL AND LUBRICATION SYSTEM
CONSTRUCTION
Top cap
Spring
Jet needle holder
Washer
Spacer
Jet needle
Piston valve/diaphragm
Diaphragm
Starter plunger
Pilot jet
Jet holder
Main jet
Pilot screw
Starter jet
Throttle stop screw
Float
Gasket
Needle valve seat
Needle valve
Float chamber
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REMOVAL
• Remove the fuel tank. (See p. 4-1.)
• Remove the starter plunger
• Loosen the lock nuts and disconnect the throttle cables
• Remove the overflow hose and air vent hose
FUEL AND LUBRICATION SYSTEM 4-4
• Loosen the clamp screws.
• Remove the carburetor.
DISASSEMBLY
• Remove the fuel hose and vacuum hose
• Remove the throttle stop screw
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4-5 FUEL AND LUBRICATION SYSTEM
Remove the diaphragm cover ©.
Remove the diaphragm
• Remove the carburetor top cap.
• Remove the spring and piston valve diaphragm
along with
• Remove the jet needle holder .
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• Remove the jet needle
Holder
Spring
Washer
Spacer
The O-ring should be replaced with a new one.
A CAUTION
• Remove the float chamber body .
FUEL AND LUBRICATION SYSTEM 4-6
• Remove the screw
• Remove the float pin
• Remove the float assembly along with the needle valve .
A CAUTION
Do not use a wire to clean the valve seat.
• Remove the screw and needle valve seat
• Remove the main jet and jet holder
• Remove the pilot jet
• Remove the starter jet
• Remove the pilot screw
NOTE:
Before removing the pilot screw , its setting must be determined. Slowly turn the pilot screw clockwise and count the number of turns until it is lightly seated. When reassembling the pilot screw, you will want to set it to its original position.
A CAUTION
Do not use a wire to clean the passage and jets.
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4-7 FUEL AND LUBRICATION SYSTEM
• Remove the pilot air jet No.1 and No.2
• Remove the needle jet
PILOT SCREW REMOVAL (For E-03, -28, -33)
Because harsh cleaning solvents can damage the O-rlng seals In the pilot system, the pilot system components should be removed before cleaning.
• Use a 1/8" size drill bit with a drill-stop to remove the pilot screw plug. Set the drill-stop 6 mm from the end of the bit to prevent drilling into the pilot screw. Carefully drill through the plug.
• Thread a self-tapping sheet metal screw into the plug.
Pull on the screw head with pliers to remove the plug.
Carefully clean any metal shavings from the area.
• Slowly turn the pilot screw clockwise and count the number of turns until the screw is lightly seated. Make a note of how many turns were made so the screw can be reset correctly after cleaning.
• Remove the pilot screw along with the spring, washer, and O-ring.
• After cleaning, reinstall the pilot screw to the original setting by turning the screw in until it lightly seats, and then backing it out the same number of turns counted during disassembly.
• Install a new plug by tapping it into place with a punch.
Drill-stop
Plug
Pilot screw
Carburetor body
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FUEL AND LUBRICATION SYSTEM 4- 8
CLEANING
AWARNING
Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer's instructions on proper use, handling and storage.
Clean all jets with a spray-type carburetor cleaner and dry them using compressed air. Clean all circuits of the carburetor thoroughly - not just the perceived problem area. Clean the circuits in the carburetor body with a spray-type cleaner and allow each circuit to soak, if necessary, to loosen dirt and varnish. Blow the body dry using compressed air.
A CAUTION
Do not use a wire to clean the jets or passageways. A wire can damage the jets and passageways. If the components cannot be cleaned with a spray cleaner it may be necessary to use a diptype cleaning solution and allow them to soak. Always follow the chemical manufacturer's instructions for proper use and cleaning of the carburetor components.
* After cleaning, reassemble the carburetor with new seals and gaskets.
INSPECTION AND ADJUSTMENT
Check the following items for any damage or clogging.
* Pilot jet
* Main jet
* Starter jet
* Diaphragm
* Pilot screw
* Needle jet air bleeding hole
* Float
* Needle valve
* Gasket and O-ring
* Pilot outlet and by-pass holes
NEEDLE VALVE INSPECTION
If foreign matter is caught between the valve seat and the needle valve, the gasoline will continue flowing and overflow. If the valve seat and needle valve are worn beyond the permissible limits, similar trouble will occur. Conversely, if the needle valve sticks, the gasoline will not flow into the float chamber. Clean the float chamber and float parts with gasoline. If the needle valve is worn, as shown in the illustration, replace it along with a new valve seat. Clean the fuel passage of the mixing chamber with compressed air.
CORRECT
INCORRECT
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4-9 FUEL AND LUBRICATION SYSTEM
FLOAT HEIGHT ADJUSTMENT
To check the float height, turn the carburetor upside down.
Measure the float height while the float arm is just contacting the needle valve using vernier calipers. Bend the tongue as necessary to bring the float height to the specified value.
Float height : 13.0 ±0.5 mm (0.51 ±0.02 in)
09900-20101: Vernier calipers
REASSEMBLY
Reassemble the carburetor in the reverse order of disassembly.
Pay attention to the following points: • Turn the throttle stop screw until the throttle valve's bottom end is aligned with the foremost by-pass port
NOTE:
When removing the throttle valve, applying a small quantity of THREAD LOCK "1342" to the throttle valve mounting screws and tighten them.
99000-32050: THREAD LOCK "1342"
A CAUTION
Face the stamped side of the throttle valve out.
• Install the needle jet as shown.
Large diameter side Bore side
Small diameter side
Main jet side
REMOUNTING
Remount the carburetor in the reverse order of removal.
* Adjust the following items to the specification.
* Engine idle r/min ............................See pp. 2-7 and -8.
* Throttle cable play ..................................... See p. 2-8.
* Starter plunger cable play ........................ See p. 2-9.
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LUBRICATION SYSTEM
OIL PRESSURE
See p. 2-19.
OIL FILTER
See pp. 2-9 and -10.
OIL SUMP FILTER
When replacing the engine oil, make sure that the oil sump filter has no tears or damage. Also, be sure to clean the oil sump filter periodically. (See pp. 3-16, -47 and -51.)
FUEL AND LUBRICATION SYSTEM 4-10
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4-11 FUEL AND LUBRICATION SYSTEM
ENGINE LUBRICATION SYSTEM CHART
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CHASSIS
--------------------------------------------
CONTENTS
----------------------------------------------
EXTERIOR PARTS
......................................................................................
5- 1
REMOVAL
.................................................................................................
5- 1
REMOUNTING
.......................................................................................
5- 1
FRONT WHEEL
..........................................................................................
5-2
CONSTRUCTION
.....................................................................................
5-2
REMOVAL
..................................................................................................
5- 3
INSPECTION AND DISASSEMBLY
.......................................................
5-3
REASSEMBLY
..........................................................................................
5- 5
REMOUNTING
........................................................................................
5- 6
FRONT BRAKE
.........................................................................................
5- 7
CONSTRUCTION
.....................................................................................
5- 7
BRAKE PAD REPLACEMENT
...............................................................
5-8
BRAKE FLUID REPLACEMENT
............................................................
5- 8
BRAKE CALIPER REMOVAL AND DISASSEMBLY
...........................
5-9
BRAKE CALIPER INSPECTION
...........................................................
5-10
BRAKE CALIPER REASSEMBLY AND REMOUNTING
..................
5-10
BRAKE DISC INSPECTION
.....................................................................
5-11
MASTER CYLINDER REMOVAL AND DISASSEMBLY
.......................
5-11
MASTER CYLINDER INSPECTION
......................................................
5-13
MASTER CYLINDER REASSEMBLY AND REMOUNTING
................
5-13
FRONT FORK
..............................................................................................
5-15
CONSTRUCTION
.....................................................................................
5-15
REMOVAL AND DISASSEMBLY
.........................................................
5-15
INSPECTION
............................................................................................
5-17
REASSEMBLY AND REMOUNTING
.....................................................
5-18
STEERING
....................................................................................................
5-22
CONSTRUCTION
.....................................................................................
5-22
REMOVAL AND DISASSEMBLY
..........................................................
5-22
INSPECTION
............................................................................................
5-25
REASSEMBLY AND REMOUNTING
.....................................................
5-26
REAR WHEEL AND REAR BRAKE
.........................................................
5-29
CONSTRUCTION
.....................................................................................
5-29
REMOVAL
.................................................................................................
5-30
INSPECTION AND DISASSEMBLY
......................................................
5-31
REASSEMBLY AND REMOUNTING
.....................................................
5-33
REAR SUSPENSION
..................................................................................
5-36
CONSTRUCTION
.....................................................................................
5-36
REMOVAL
.................................................................................................
5-37
INSPECTION AND DISASSEMBLY
......................................................
5-38
REASSEMBLY AND REMOUNTING
....................................................
5-40
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5-1 CHASSIS
EXTERIOR PARTS
REMOVAL
FRONT SEAT
• Remove the seat with the ignition key.
RIGHT FRAME COVER
• Remove the screw.
• Remove the right frame cover.
LEFT FRAME COVER
• Remove the screw.
• Remove the left frame cover.
hooked part
hooked part
• Remove the seat lock.
REAR SEAT
• Remove the rear seat by removing the bolts.
REMOUNTING
Remount the seats, frame covers, front and rear fenders in the reverse order of removal.
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FRONT WHEEL
CONSTRUCTION
CHASSIS 5-2
Dust cover
Spacer
Bearing
Front w heel
Spacer
Bearing
Brake disc
Speedometer gearbox
Front axle Axle pinch bolt Brake disc bolt
ITEM N-m
65
23
23 kg-m
6.5
2.3
2.3
Ib-ft
47.0
16.5
16.5
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Left
Right
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5-3 CHASSIS
REMOVAL
FRONT WHEEL
• Loosen the axle pinch bolt
• Loosen the front axle
• Raise the front wheel off the ground with a jack or wooden block.
• Remove the front wheel by removing the front axle
• Remove the dust cover and spacer
• Remove the brake disc.
09900-00410: Hexagon wrench set
INSPECTION AND DISASSEMBLY
SPEEDOMETER GEARBOX
Turn the speedometer gear and check to see that the gear turns smoothly together with the speedometer pinion.
WHEEL BEARINGS
Inspect the play of the wheel bearings by hand while they are in the wheel. Rotate the inner race by hand to inspect it for abnormal noise and smooth rotation. Replace the wheel bearings if there is anything unusual.
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Remove the wheel bearings as follows:
• Insert the adapter into the wheel bearing.
• After inserting the wedge bar from the opposite side, lock the wedge bar into the slit of the adapt er.
• Drive out both bearings by striking the wedge bar.
09941-50111: Bearing remover
A CAUTION
The removed bearings should be replaced with new ones.
FRONT AXLE
Measure the front axle runout using the dial gauge. If the runout exceeds the limit, replace the front axle.
09900-20606: Dial gauge (1/100) 09900-
20701: Magnetic stand 09900-21304: Vblock set (100 mm)
Service Limit: 0.25 mm (0.010 in)
WHEEL
Make sure that the wheel runout (axial and radial) does not exceed the service limit when checked as shown. An excessive amount of runout is usually due to worn or loose wheel bearings and can be corrected by replacing the bearings. If bearing replacement fails to reduce the runout, replace the wheel.
Service Limit (axial and radial): 2.0 mm (0.08 in)
SPOKE NIPPLE
Check to be sure that all nipples are tight, and retight en them as necessary using a spoke nipple wrench.
09940-60113: Spoke nipple wrench Spoke nipple: 4.5 N-m (0.45 kg-m, 3.5 Ib-ft)
CHASSIS 5-4
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5-5 CHASSIS
REASSEMBLY
• Apply SUZUKI SUPER GREASE "A" to the bearings before installing.
99000-25010: SUZUKI SUPER GREASE "A"
• Install the wheel bearings using the special tools as described below.
09924-84510: Bearing installer set
09924-84521: Bearing installer set
CAUTION
* First install the left wheel bearing, then install the right wheel bearing.
* The sealed cover on the bearings must face to the outside.
Left side
Right side
Left side Right side
BRAKE DISC
• Make sure that the brake disc is clean and free of any grease. Apply THREAD LOCK SUPER "1360" to the brake disc bolts and tighten them to the specified torque.
99000-32130: THREAD LOCK SUPER "1360"
Brake disc bolt: 23 N-m (2.3 kg-m, 16.5 Ib-ft)
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Spacer
REMOUNTING
Remount the front wheel in the reverse order of removal.
Pay attention to the following points:
• Apply SUZUKI SUPER GREASE "A" to the speedometer gearbox.
99000-25010: SUZUKI SUPER GREASE "A"
• Align the lugs on the speedometer gearbox with the recesses on the front wheel.
• Set the speedometer gearbox with cable as shown in the illustration.
• Tighten the front axle to the specified torque.
Front axle: 65 N-m (6.5 kg-m, 47.0 Ib-ft)
• Tighten the axle pinch bolt @ to the specified torque.
Axle pinch bolt: 23 N-m (2.3 kg-m, 16.5 Ib-ft)
CHASSIS 5-6
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5-7 CHASSIS
FRONT BRAKE
CONSTRUCTION
ITEM N-m
23
10
39
18
7.5
kg-m kg-m
2.3
16.5
1.0
7.0
3.9
1.8
0.75
28.0
13.0
5.5
Reservoir cap
Diaphragm
Brake piston/primary cup
Brake hose
Brake caliper holder
Brake pad
Spring
Dust seal
Piston seal
Piston
Brake hose union bolt
Brake master cylinder mounting bolt
Brake caliper mounting bolt
Brake pad mounting bolt
Brake caliper air bleeder valve
¿WARNING
This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix different types of fluid, such as silicone-based or petroleum-based brake fluids. Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or which stored for long periods of time. When storing the brake fluid, seal the container completely and keep it away from children.
When replenishing brake fluid, take care not to get dust into the fluid. When washing brake components, use new brake fluid. Never use cleaning solvent. A contaminated brake disc or brake pad reduces braking performance. Discard contaminated pads and clean the disc with high quality brake cleaner or a neutral detergent.
A CAUTION
Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials etc.
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BRAKE PAD REPLACEMENT
• Loosen the brake pad mounting bolt
• Remove the brake caliper mounting bolts
• Remove the brake pad mounting bolt
• Remove the brake pads
A CAUTION
* Do not operate the brake lever during or after brake pad removal.
* Replace the brake pads as a set, otherwise braking performance will be adversely affected.
• Install the new brake pads and brake pad mounting bolt.
• Tighten the brake caliper mounting bolts and brake pad mounting bolt to the specified torque.
Brake caliper mounting bolt: 39 N-m
(3.9 kg-m, 28.0 Ib-ft)
Brake pad mounting bolt: 18 N-m
(1.8 kg-m, 13.0 Ib-ft)
NOTE:
After replacing the brake pads, pump with the brake lever a few times to operate the brake correctly and then check the brake fluid level.
BRAKE FLUID REPLACEMENT
• Place the motorcycle on a level surface and keep the handlebars straight.
• Remove the master cylinder reservoir cap and diaphragm
• Suck up the old brake fluid as much as possible.
• Fill the reservoir with new brake fluid.
Specification and Classification: DOT 4
• Connect a cleaner hose to the air bleeder valve and insert the free end of hose into a receptacle.
• Loosen the air bleeder valve and pump the brake lever until the old brake fluid is completely out of the brake system.
• Close the air bleeder valve and disconnect the clear hose. Fill the reservoir with new brake fluid to the upper end of the inspection window.
A CAUTION
Bleed air from the brake system. (See p. 2-13.)
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CHASSIS 5-8
5-9 CHASSIS
BRAKE CALIPER REMOVAL AND
DISASSEMBLY
• Disconnect the brake hose from the brake caliper by removing the brake hose union bolt and allow the brake fluid to drain into a suitable receptacle.
• Loosen the brake pad mounting bolt.
• Remove the brake caliper by removing the mounting bolts .
A CAUTION
Never reuse the brake fluid left over from previous servicing and which has been stored for long periods of time.
AWARNING
Brake fluid if it leaks, will interfere with safe running and discolor painted surfaces. Check the brake hose and hose joints for cracks and oil leakage.
• Remove the brake pads. (See p. 5-8.)
• Remove the brake caliper holder
• Remove the spring
• Place a rag over the brake caliper piston to prevent it from popping out and then force out the piston using compressed air.
A CAUTION
Do not use high pressure air to prevent brake caliper piston damage.
• Remove the dust seal and piston seal
A CAUTION
Do not reuse the dust seal and piston seal to prevent brake fluid leakage.
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CHASSIS 5-10
BRAKE CALIPER INSPECTION
BRAKE CALIPER
Inspect the brake caliper cylinder wall for nicks, scratches or other damage.
BRAKE CALIPER PISTONS
Inspect the brake caliper piston for any scratches or other damage.
BRAKE CALIPER REASSEMBLY AND
REMOUNTING
Reassemble and remount the brake caliper in the reverse order of removal and disassembly. Pay attention to the following points: • Wash the caliper bore and piston with the specified brake fluid. Thoroughly wash the dust seal groove and piston seal groove.
Specification and Classification: DOT 4
A CAUTION
* Wash the brake caliper components with new brake fluid before reassembly.
* Do not wipe the brake fluid off after washing the components.
* When washing the components, use the specified brake fluid. Never use different types of fluid or cleaning solvents such as gasoline, ker-osine, etc.
* Replace the piston seal and dust seal with new ones.
* Apply brake fluid to all of the seals, brake caliper bore and piston before reassembly.
• Install the piston seal as shown in the illustration.
• Apply grease to the brake caliper holder.
99000-25100: SUZUKI SILICONE GREASE
Dust seal
Piston seal
Caliper body
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5-11 CHASSIS
• Tighten the brake caliper mounting bolts and brake pad mounting bolt to the specified torque.
• Tighten the brake hose union bolt
to the specified torque.
Brake caliper mounting bolt
39 N-m (3.9 kg-m, 28.0 Ib-ft)
Brake pad mounting bolt : 18 N-m
(1.8 kg-m, 13.0 Ib-ft)
Brake hose union bolt : 23 N-m
(2.3 kg-m, 16.5 Ib-ft)
NOTE:
Before remounting the brake caliper, push the brake caliper piston all the way into the caliper.
A CAUTION
Bleed air from the system after reassembling the brake caliper. (See p. 2-13.)
BRAKE DISC INSPECTION
• Remove the front wheel. (See p. 5-3.)
Check the brake disc for damage or cracks. Measure the thickness using the micrometer.
Replace the brake disc if the thickness is less than the service limit or if damage is found.
09900-20205: Micrometer (0-25 mm)
Service Limit Brake disc thickness: 4.5 mm
(0.18 in)
Measure the runout using the dial gauge.
Replace the brake disc if the runout exceeds the service limit.
09900-20606: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
Service Limit Brake disc runout: 0.30 mm (0.012 in)
• If either measurement exceeds the service limit, replace the brake disc. (See pp. 5-3 and -5.)
• Install the front wheel. (See p. 5-6.)
MASTER CYLINDER REMOVAL AND
DISASSEMBLY
• Disconnect the front brake light switch lead wires
• Remove the brake lever
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• Place a rag underneath the brake hose union bolt on the master cylinder to catch any spilt brake fluid.
• Remove the brake hose union bolt.
A CAUTION
Immediately wipe off any brake fluid contacting any part of the motorcycle. The brake fluid reacts chemically with paint, plastics and rubber materials, etc. and will damage them severely.
• Remove the master cylinder assembly.
• Remove the front brake light switch
• Remove the reservoir cap and diaphragm
• Drain the brake fluid.
• Remove the dust boot
• Remove the circlip using the special tool.
09900-06108: Snap ring pliers
CHASSIS 5-12
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5-13 CHASSIS
• Remove the piston/secondary cup and return spring
MASTER CYLINDER INSPECTION
Inspect the master cylinder bore for any scratches or other damage.
Inspect the piston surface for any scratches or other damage.
Inspect the primary cup, secondary cup and dust seal for wear or damage.
MASTER CYLINDER REASSEMBLY AND
REMOUNTING
Reassemble and remount the master cylinder in the reverse order of removal and disassembly. Pay attention to the following points:
A CAUTION
* Wash the master cylinder components with new brake fluid before reassembly.
* Do not wipe the brake fluid off after washing the components.
* When washing the components, use the specified brake fluid. Never use different types of fluid or cleaning solvents such as gasoline, kerosine, etc.
* Apply brake fluid to the master cylinder bore and all of the master cylinder components before reassembly.
Specification and Classification: DOT 4
NOTE:
When installing the circlip, make sure that the sharp edge of the circlip faces outside.
• When reinstalling the brake light switch, align the projection on the switch with the hole in the master cylinder.
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CHASSIS 5-14
• When remounting the master cylinder onto the handlebars, align the master cylinder holder's mating surface
with punch mark on the handlebars and tighten the upper clamp bolt first.
Master cylinder bolt: 10 N-m (1.0 kg-m, 7.0 Ib-ft)
• Install the brake hose union as shown and tighten the union bolt to the specified torque.
Brake hose union bolt: 23 N-m (2.3 kg-m, 16.5 Ib-ft)
A CAUTION
Bleed air from the brake system after reassembling the master cylinder. (See p. 2-13.)
Upper clamp bolt
Handlebars
Master cylinder
Clearance
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5-15 CHASSIS
FRONT FORK
CONSTRUCTION
ITEM N-m
23
20 kg-m Ib-ft
2.3 16.5
2.0 14.5
REMOVAL AND DISASSEMBLY
• Remove the front wheel. (See p. 5-3.)
• Remove the brake caliper. (See p. 5-9.)
A CAUTION
Secure the brake caliper to the frame with a string etc., taking care not to bend the brake hose.
• Remove the speedometer cable guide from the left fork leg.
• Remove the front fender and brake hose guide
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O-ring
Spacer
Washer
Front fork spring
Damper rod ring
Damper rod
Rebound spring
Inner tube
Dust seal
Oil seal stopper ring
Oil seal
Washer
Slide metal
Guide bushing
Oil lock piece
Outer tube
Gasket
Front fork cap bolt
Damper rod bolt
• Remove the front fork after loosening the front fork upper and lower clamp bolts
NOTE:
Slightly loosen the front fork cap bolt to facilitate later disassembly.
• Remove the front fork cap bolt , spacer , washer and spring
• Invert the front fork and stroke it several times to drain out the fork oil.
• Hold the front fork in the inverted position for a few minutes to allow the fork oil to fully drain.
• Remove the dust seal and oil seal stopper ring
• Remove the damper rod bolt
09900-00410: Hexagon wrench set
CHASSIS 5-16
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5-17 CHASSIS
• Remove the damper rod and rebound spring from the inner tube.
• Separate the inner tube from the outer tube.
• Remove the following parts.
Oil seal Washer
Outer tube slide metal
Inner tube slide metal
The removed oil seal and slide metals should be replaced with new ones.
A CAUTION
• Remove the oil lock piece from the outer tube.
INSPECTION
DAMPER ROD RING
Inspect the damper rod ring for wear or damage. If it is worn or damaged, replace it with a new one.
FRONT FORK SPRING
Measure the fork spring free length. If it is shorter than the service limit, replace it with a new one.
Service Limit: 301 mm (11.9 in)
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INNER AND OUTER TUBES
Inspect the inner tube sliding surface and outer tube sliding surface for scuffing.
REASSEMBLY AND REMOUNTING
Reassemble and remount the front fork in the reverse order of removal and disassembly. Pay attention to the following points:
I A CAUTION !
* Wash each metal part with cleaning solvent before reassembly.
* Never reuse fork oil left over from the last servicing.
* Replace the oil seal and dust seal with new ones during reassembly.
• Hold the inner tube vertically, clean the metal groove and install the slide metal by hand.
I A CAUTION !
Do not damage the Teflon coated surface of the inner tube's slide metal when mounting it.
• Install the outer tube metal , washer and oil seal to the inner tube.
IA CAUTION]
* When installing the oil seal onto the inner tube, protect their seal lips to prevent seal lip damage.
* Before installing the oil seal, apply SUZUKI SU
PER GREASE "A" to its seal lip lightly.
99000-25010: SUZUKI SUPER GREASE "A"
CHASSIS 5-18
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5-19 CHASSIS
• Tighten the damper rod bolt to the specified torque.
09900-00410: Hexagon wrench set
Front fork damper rod bolt: 20 N-m
(2.0 kg-m, 14.5 Ib-ft)
CAUTION
Use a new damper rod gasket to prevent oil leakage.
• Install the oil seal stopper ring and dust seal
A CAUTION
Make sure that the oil seal stopper ring is fitted securely.
NOTE:
Before installing the dust seal , apply a small quantity of
SUZUKI SUPER GREASE "A" to the lip of dust seal.
99000-25010: SUZUKI SUPER GREASE "A"
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• Pour the specified fork oil into the inner tube.
Fork oil type: SUZUKI FORK OIL SS-08 (#10)
99000-99001-SS8: SUZUKI FORK OIL SS-08
Specification
Front fork oil capacity (each leg):
369 ml (12.5/13.0 US/Imp oz)
• Hold the front fork leg in a vertical position and adjust the fork oil level using the special tool.
09943-74111: Fork oil level gauge
Specification
Front fork oil level: 105 mm (4.1 in)
NOTE:
When adjusting the oil level, remove the fork spring and compress the inner tube fully.
• Install the fork spring as shown.
NOTE:
The end of the fork spring with the smaller pitch should be at the bottom of the front fork.
• Install the front fork cap bolt to the inner tube.
A CAUTION
Use a new O-ring to prevent oil leakage.
• Install the front fork to the motorcycle.
• Align the upper surface of the inner tube with the upper surface of the steering stem upper bracket
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CHASSIS 5-20
5-21 CHASSIS
• Tighten the front fork lower clamp bolts and front fork cap bolts to the specified torque.
• Tighten the front fork upper clamp bolts to the specified torque.
Front fork upper clamp bolt: 23 N-m
(2.3 kg-m, 16.5 Ib-ft)
Front fork lower clamp bolt: 33 N • m
(3.3 kg-m, 24.0 Ib-ft)
Front fork cap bolt: 23 N-m (2.3 kg-m, 16.5 Ib-ft)
• Install the front fender and tighten the mounting bolts temporarily.
• Install the front brake caliper. (See p. 5-10.)
• Install the front wheel. (See p. 5-8.)
• Move the front fork up and down several times.
• Tighten the front fender mounting bolts securely.
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CHASSIS 5-22
STEERING
CONSTRUCTION
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ITEM N-m
65
16
45
23
33 kg-m
6.5
1.6
4.5
2.3
3.3
Ib-ft
47.0
11.5
32.5
16.5
24.0
Steering stem upper bracket
Handlebar clamp
Handlebar holder
Steering stem nut
Dust seal
Bearing, upper
Bearing, low er
Steering stem
Steering stem low er cover
Handlebars
Handlebar balancer
Steering stem head bolt
Handlebar clamp bolt
Handlebar holder nut Front fork upper clamp bolt Front fork low er clamp bolt
REMOVAL AND DISASSEMBLY
• Remove the front wheel. (See p. 5-4.)
• Remove the front fork. (See p. 5-15.)
• Disconnect the front brake light switch lead wires.
• Remove the front brake master cylinder.
• Remove the right handlebar balancer .
• Remove the handlebar right switch
• Disconnect the throttle cables and remove the throttle grip .
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5-23 CHASSIS
• Remove the left handlebar balancer .
• Remove the handlebar left switch
• Disconnect the clutch lever position switch coupler
• Remove the rear view mirror
• Disconnect the clutch cable.
• Remove the handlebar clamp bolt caps.
• Remove the handlebars by removing the handlebar clamp bolts.
• Remove the headlight.
• Disconnect the headlight coupler.
• Disconnect the lead wire couplers.
• Remove the headlight housing mounting nut.
by removing the
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CHASSIS 5-24
• Remove the steering stem lower cover
• Remove the front brake hose/speedometer cable guide
• Disconnect the speedometer cable
• Remove the speedometer .
^5© - TJ«E
• Remove the front turn signal light brackets.
• Remove the handlebar holders
• Remove the steering stem head bolt
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5-25 CHASSIS
• Remove the steering stem nut using the special tool.
09940-14911: Steering stem nut wrench
• Draw out the steering stem lower bracket.
NOTE:
Hold the steering stem lower bracket to prevent it from falling.
• Remove the dust seal , upper bearing inner race and upper bearing
• Remove the lower bearing
• Remove the ignition switch using the special tool.
09930-11920: Torx bit JT40H
09930-11940: Bit holder
INSPECTION
Inspect the removed parts for the following abnormalities.
* Handlebar distortion
* Handlebar clamp wear
* Race wear and brinelling
* Bearing wear or damage
* Abnormal bearing noise
* Distortion of the steering stem
• Remove the lower bearing outer race using a chisel.
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• Drive out the steering stem upper and lower bearing races using the special tool.
09941-54911: Bearing outer race remover
09941-74910: Steering bearing installer
REASSEMBLY AND REMOUNTING
Reassemble and remount the steering stem in the reverse order of removal and disassembly. Pay attention to the following points:
• Press in the upper and lower outer races using the special tool.
09941-34513: Steering race installer
• Press ¡n the steering stem lower race using the special tool.
09941-74910: Steering bearing installer
• Apply grease to the upper and lower bearings.
99000-25010: SUZUKI SUPER GREASE "A"
• Tighten the steering stem nut using the special tool.
09940-14911: Steering stem nut wrench
Steering stem nut: 45 N ■ m (4.5 kg-m, 32.5 Ib-ft)
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CHASSIS 5-26
5-27 CHASSIS
• Turn the steering stem lower bracket about fi ve or six times to the left and right.
• Loosen the steering stem nut of a turn
NOTE:
This adjustment will vary from motorcycle to motorcycle. Mak e sure that the steering turns smoothly and easily in both directions.
• Install the steering stem upper bracket
• Install the right and left front forks.
• Tighten the front fork lower clamp bolts.
• Tighten the steering stem head bolt to the specified torque.
Steering stem head bolt: 65 N ■ m (6.5 kg-m, 47.0 Ib-ft)
• Align the upper surface of the front fork inner tube with the upper surfac e of the steering stem upper bracket.
• Tighten the upper and lower front fork clamp bolts to the specified torque.
_ Front fork clamp bolt upper: 23 N-m (2.3 kg-m, 16.5 Ib-ft) lower: 33 N-m (3.3 kg-m, 24.0 Ib-ft)
• Install the handlebar holders
and tight en their nuts temporarily.
• Install the handlebars with the punc h mark aligned with the handlebar clamp as shown.
• Tighten the handlebar clamp bolts to the specified torque.
Handlebar clamp bolt: 16 N-m (1.6 kg-m, 11.5 Ib-ft)
NOTE:
The gap between the handlebar clamp and holder should be even.
• Tighten the handlebar holder nuts to the specified torque.
Handlebar holder nut: 45 N-m (4.5 kg-m, 32.5 Ib-ft)
• Install the handlebar clamp bolt caps.
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NOTE:
When installing the front turn signal lights, insert the projection on the turn signal light bracket into the hole of steering stem upper bracket.
• Install the handlebar left switch.
NOTE:
Insert the projection into the hole of the handlebars.
* Install the handlebar right switch.
NOTE:
* Apply SUZUKI SUPER GREASE "A" to the end of the throttle cable.
99000-25010: SUZUKI SUPER GREASE "A"
* Insert the projection into the hole of the handlebars.
• Install the master cylinder. (See p. 5-13.)
• Install the front brake caliper. (See p. 5-10.)
• Install the front fender and front wheel. (See pp. 5-6 and
-21.)
NOTE:
Hold the front fork legs, move them back and forth and make sure that the steering is not loose.
A CAUTION
After performing the adjustment and installing the handlebars, "rock" the front wheel assembly forward and backward to ensure that there is no play and that the procedure was accomplished correctly. Finally, check to make sure that the steering stem moves freely from left to right with its own weight. If play or stiffeness is noticeable, re-adjust the steering stem nut.
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CHASSIS 5-28
5-29 CHASSIS
REAR WHEEL AND REAR BRAKE
CONSTRUCTION
Spacer
Brake panel
Brake shoe
Spring
Bearing
Spacer
Brake camshaft
Rear w heel
Bearing
Damper
Drive chain guide
Rear sprocket mounting drum
Retainer
Bearing
Dust seal
Spacer
Rear sprocket
Rear axle
Rear axle nut
Rear brake cam lever nut
Rear sprocket mounting nut
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ITEM N-m
78
10
50 kg-m kg-m
7.8
1.0
5.0
56.5
7.0
36.0
REMOVAL
• Remove the clip and rear brake adjusting nut
• Remove the cotter pin, torque link nut and bolt.
• Remove the rear axle nut
• Raise the rear wheel off the ground with a jack or wooden block.
• Loosen the drive chain adjusting nuts , left and right.
• Remove the rear axle.
• Disengage the drive chain from the rear sprocket.
• Remove the rear wheel.
• Remove the rear brake panel
• Remove the rear sprocket with mounting drum from the rear wheel.
NOTE:
Before separating the rear sprocket and mounting drum, slightly loosen the rear sprocket bolts.
• Remove the rear sprocket damper
• Remove the drive chain guide and rear sprocket from the rear sprocket mounting drum.
• Remove the brake shoes from the brake panel.
CHASSIS 5-30
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5-31 CHASSIS
• Remove the brake cam lever bolt and nut.
• Remove the brake cam lever
• Remove the washer , O-ring and brake camshaft
INSPECTION AND DISASSEMBLY
WHEEL BEARING ............................ See pp. 5-3 and -4.
WHEEL AXLE ................................................ See p. 5-4.
WHEEL .......................................................... See p. 5-4.
SPOKE NIPPLE ........................................... See p. 5-4.
REAR SPROCKET MOUNTING
DRUM BEARING ......................................... See p. 5-3.
* Inspect of the rear sprocket mounting drum bearing in the same manner as the wheel bearing.
Remove the rear sprocket mounting drum bearing as follows. • Remove the dust seal using the special tool.
09913-50121: Oil seal remover
A CAUTION
The removed dust seal should be replaced with a new one.
• Remove the rear sprocket mounting drum bearing using the special tool.
09941-50111: Bearing remover
A CAUTION
The removed bearing should be replaced with a new one.
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• Remove the retainer
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 Service Limit: 130.7 mm
(5.15 in)
BRAKE SHOES
Check the brake shoes and decide whether it should be replaced or not from the thickness of the brake shoe lining.
Service Limit: 1.5 mm (0.06 in)
A CAUTION
Replace the brake shoes as a set, otherwise braking performance will be adversely affected.
REAR SPROCKET DAMPER
Inspect the rear sprocket damper for wear and damage.
Replace the rear sprocket damper if there is anything unusual.
REAR SPROCKET
Inspect the sprocket's teeth for wear. If they are worn, replace the sprocket and drive chain as a set.
Normal wear
Excessive wear
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CHASSIS 5-32
5-33 CHASSIS
REASSEMBLY AND REMOUNTING
Reassemble and remount the rear wheel and rear brake in the reverse order of removal and disassembly. Pay attention to the following points:
WHEEL BEARING
• Apply SUZUKI SUPER GREASE "A" to the bearing be fore installation.
99000-25010: SUZUKI SUPER GREASE "A"
• Press fit the bearing to the wheel using the special tools.
09924-84510: Bearing installer set
09924-84521: Bearing installer set
A CAUTION
* First install the right wheel bearing, then left wheel bearing.
* The sealed cover on the bearing must face out.
Left side Right side
Right bearing
Left side
Left bearing
Right side
Spacer
Clearance
REAR SPROCKET MOUNTING DRUM BEARING
• Install the rear sprocket mounting drum bearing and dust seal using the special tool.
09913-76010: Bearing installer
NOTE:
Apply grease to the bearing and dust seal lip before assembling the rear sprocket mounting drum.
99000-25010: SUZUKI SUPER GREASE "A"
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REAR SPROCKET
• Tighten the rear sprocket nuts to the specified torque.
Rear sprocket nut: 50 N-m (5.0 kg-m, 36.0 Ib-ft)
NOTE:
The stamped mark on the rear sprocket should face to the outside.
CHASSIS 5-34
BRAKE CAMSHAFT
• When installing the brake camshaft, apply SUZUKI SU-
PER GREASE "A" to the camshaft.
99000-25010: SUZUKI SUPER GREASE "A"
BRAKE CAM LEVER
• Install the new O-ring and washer
• Align the notch on the brake camshaft with the slit in the brake cam lever as shown.
• Tighten the brake cam lever nut to the specified torque.
Brake cam lever nut: 10 N-m (1.0 kg-m, 7.0 Ib-fl)
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5-35 CHASSIS
• Apply SUZUKI SUPER GREASE "A" to the brake cam and pin, and install the brake shoes.
99000-25010: SUZUKI SUPER GREASE "A"
A CAUTION
Be careful not to apply too much grease to the cam and pin. If grease gets on the lining, brake slippage will result.
REAR WHEEL
• Tighten the rear torque link nut to the specified torque and install the new cotter pin.
Rear torque link nut: 13 N-m (1.3 kg-m, 9.5 Ib-ft)
• Adjust the drive chain slack after installing the rear wheel. (See p. 2-11.)
• Tighten the rear axle nut to the specified torque.
Rear axle nut: 78 N-m (7.8 kg-m, 56.5 Ib-ft)
• Tighten both chain adjusting nuts securely.
• Adjust the rear brake pedal free travel. (See p. 2-14.)
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REAR SUSPENSION
CONSTRUCTION
CHASSIS 5-36
Rear shock absorber
Rear torque link
Sw ingarm
Spacer
Dust seal
Dust seal
Spacer
Drive chain buffer
Sw ingarm pivot shaft
Rear shock absorber nut
Rear torque link nut Rear shock absorber bolt
Sw ingarm pivot nut
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Left side
ITEM N-m
29
13
29
72 kg-m
2.9
1.3
2.9
7.2
Ib-ft
21.0
9.5
21.0
52.0
Right side
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5-37 CHASSIS
REMOVAL
• Remove the rear wheel. (See p. 5-30.)
• Remove the drive chain case.
• Remove the rear brake cable holder
• Remove the rear brake cable from the swingarm.
• Remove the shock absorbers .
• Remove the swingarm pivot shaft end caps.
• Remove the swingarm pivot nut and washer.
• Remove the swingarm by removing the pivot shaft.
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• Remove the rear torque link from the swingarm.
• Remove the chain buffer from the swingarm.
• Remove the spacers
INSPECTION AND DISASSEMBLY
SWINGARM PIVOT SPACERS AND DUST SEALS
Inspect the swingarm pivot spacers and dust seals for damage. If any defects are found, replace the spacer with a new one.
SWINGARM NEEDLE BEARINGS
Insert the spacers into the needle bearings, move the spacer up and down and check for any play. If there is excessive play, replace the bearing(-s) with a new one.
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CHASSIS 5-38
5-39 CHASSIS
• Remove the swingarm needle bearings using the special tools.
09923-74510: Bearing remover
09930-30102: Sliding shaft
A CAUTION
The removed needle bearings should be replaced with new ones.
SWINGA RM
Inspect the swingarm for damage.
If any defects are found, replac e the swingarm with a new one.
CHAIN BUFFER
Inspect the chain buffer for wear and damage. If any de fects are found, replac e the chain buffer with a new one.
SWINGARM PIVOT SHAFT
Measure the pivot shaft runout using the dial gauge. If the pivot shaft exceeds the service limit, replace it with a new one.
09900-20606: Dial gauge (1/100 mm) 09900-
20701: Magnetic stand 09900-21304: Vblock (100 mm)
Service Limit: 0.3 mm (0.01 in)
REAR SHOCK ABSORBER
Inspect the rear shock absorber for damage and oil leak age.
If any defects are found, replace the rear s hock ab sorber with a new one.
A CAUTION
Do not attempt to disassemble the rear shock absorber. It is unserviceable.
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REASSEMBLY AND REMOUNTING
Reassemble and remount the swingarm and rear shock absorber in the reverse order of removal and disassembly.
Pay attention to the following points: • Press the needle bearings into the swingarm pivot using a suitable socket and the special tool. (See p. 5-36.)
09924-84521: Bearing installer set
NOTE:
Install the needle bearings with the stamped mark facing out.
• Apply grease to the spacers, dust seals and needle bearings.
99000-25010: SUZUKI SUPER GREASE "A"
• Install the rear torque link to the swingarm.
• Tighten the rear torque link nut to the specified torque.
Rear torque link nut: 13 N-m (1.3 kg-m, 9.5 Ib-ft)
• Install the new cotter pin.
• Install the swingarm and tighten the swingarm pivot nut to the specified torque.
Swingarm pivot nut: 72 N■ m (7.2 kg-m, 52.0 Ib-ft)
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CHASSIS 5-40
5-41 CHASSIS
• Install the rear shock absorber and tighten the mounting bolts and nuts to the specified torque.
Shock absorber mounting bolt/nut: 29 N-m
(2.9kg-m,21.0lb-ft)
NOTE:
Install the rear shock absorbers with the spring tension adjusting holes facing out.
• Install the rear wheel and rear brake. (See p. 5-35.)
• Adjust the rear shock absorber spring pre-load.
Spring pre-load (STD): 3/5 position
After installing the rear suspension and rear wheel, adjust the following before riding.
* Drive chain slack .......................................See p. 2-11
* Rear brake pedal free travel .....................See p. 2-14
* Tire pressure..............................................See p. 2-15
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ELECTRICAL SYSTEM
--------------------------------------------
CONTENTS
---------------------------------------------
CAUTIONS IN SERVICING
........................................................................
6- 1
LOCATION OF ELECTRICAL COMPONENTS
.....................................
6-3
CHARGING SYSTEM
................................................................................
6-5
DESCRIPTION
..........................................................................................
6- 5
TROUBLESHOOTING
.............................................................................
6- 6
INSPECTION
............................................................................................
6- 7
STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK
SYSTEM
........................................................................................................
6-10
STARTER SYSTEM DESCRIPTION
......................................................
6-10
SIDE-STAND/IGNITION INTERLOCK SYSTEM DESCRIPTION ... 6-10
TROUBLESHOOTING
...............................................................................
6-11
STARTER MOTOR REMOVAL AND DISASSEMBLY
.........................
6-12
STARTER MOTOR INSPECTION
..........................................................
6-12
STARTER MOTOR REASSEMBLY
........................................................
6-13
STARTER RELAY INSPECTION
...........................................................
6-14
SIDE-STAND/IGNITION INTERLOCK SYSTEM PART
INSPECTION
............................................................................................
6-15
IGNITION SYSTEM
....................................................................................
6-18
DESCRIPTION
.........................................................................................
6-18
TROUBLESHOOTING
.............................................................................
6-19
INSPECTION
.............................................................................................
6-20
SPEEDOMETER
...........................................................................................
6-24
REMOVAL AND DISASSEMBLY
..........................................................
6-24
INSPECTION
.............................................................................................
6-25
LAMPS
...........................................................................................................
6-26
HEADLIGHT AND POSITION LIGHT
....................................................
6-26
BRAKE LIGHT/TAILLIGHT
....................................................................
6-27
TURN SIGNAL LIGHTS
.........................................................................
6-28
RELAYS
.........................................................................................................
6-29
STARTER RELAY
....................................................................................
6-29
TURN SIGNAL/SIDE-STAND RELAY
....................................................
6-29
SWITCHES
.................................................................................................
6-30
BATTERY
......................................................................................................
6-31
SPECIFICATIONS
..................................................................................
6-31
INITIAL CHARGING
.................................................................................
6-31
SERVICING
...............................................................................................
6-32
RECHARGING OPERATION
..................................................................
6-33
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6-1 ELECTRICAL SYSTEM
CAUTIONS IN SERVICING
CONNECTORS
• When disconnecting a connector, be sure to hold the terminals; do not pull the lead wires.
• When connecting a connector, push it in so it is firmly attached.
• Inspect the connector for corrosion, contamination and any breakage in the cover.
COUPLERS
• With a lock-type coupler, be sure to release the lock before disconnecting it. When connecting a connector, push it in until the lock clicks shut.
• When disconnecting the coupler, be sure to hold the coupler; do not pull the lead wires.
• Inspect each terminal on the coupler for looseness or bends.
• Inspect each terminal for corrosion and contamination.
CLAMPS
• Refer to "WIRE, CABLE AND HOSE ROUTING" (See pp. 7-11 to -18.) for proper clamping procedures.
• Bend the clamp properly, as shown in the illustration.
• When clamping the wire harness, do not allow it to hang down.
• Do not use wire or any other substitute for the band-type clamp.
CORRECT INCORRECT
FUSES
• When a fuse blows, always investigate the cause, correct the problem and then replace the fuse.
• Do not use a fuse of a different capacity.
• Do not use any substitute for the fuse (e.g., wire).
SEMI-CONDUCTOR EQUIPPED PARTS
• Do not drop any part that contains a semi-conductor
(e.g., ignitor unit, regulator/rectifier).
• When inspecting the part, follow the inspection instructions carefully. Neglecting proper procedures may cause this part to be damaged.
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BATTERY
• The MF battery used in this motorcycle does not require maintenance (e.g., electrolyte level inspection, distilled water replenishing).
• During normal charging, no hydrogen gas is produced.
However, if the battery is overcharged, hydrogen gas may be produced. Therefore, be sure that there are no fire or spark sources nearby (e.g., short-circuit) when charging the battery.
• Be sure to recharge the battery in a well-ventilated and open area.
• Note that the charging system for the MF battery is different from that of a conventional battery. Do not replace the MF battery with a conventional battery.
CONNECTING THE BATTERY
• When disconnecting terminals from the battery for disassembly or servicing, be sure to disconnect the battery
( ) lead wire, first.
• When connecting the battery lead wires, be sure to connect the battery ( ) lead wire, first.
• If the terminal is corroded, remove the battery, pour warm water over it and clean it using a wire brush.
• After connecting the battery, apply a light coat of grease to the battery terminals.
• Reinstall the cover over the battery ( ) terminal.
WIRING PROCEDURE
• Properly route the wire harness according to "WIRE,
CABLE AND HOSE ROUTING". (See pp. 7-11 to -18.)
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, turn the switch to the OFF position.
CAUTION
Before using the multi circuit tester, read its instruction manual.
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ELECTRICAL SYSTEM 6-2
6-3 ELECTRICAL SYSTEM
LOCATION OF ELECTRICAL COMPONENTS
Clutch lever position switch
Ignitor
Turn signal/side-stand relay
Fuse box
Ignition coil
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Horn
Generator
Neutral switch
Side-stand switch
Regulator/rectifier
ELECTRICAL SYSTEM 6-4
Starter relay
Main fuse
Battery
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Front brake light switch
Rear brake light switch
Starter motor
6-5 ELECTRICAL SYSTEM
CHARGING SYSTEM
DESCRIPTION
The circuit of the charging system is indicated in the figure, which is composed of an AC generator, regulator/rectifier unit and battery.
The AC current generated from AC generator is converted by rectifier and is turned into DC current, then it charges the battery.
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ELECTRICAL SYSTEM 6-6
TROUBLESHOOTING
Battery runs down quickly.
Check accessories which use exces sive amounts of electricity.
No accessories
Check the battery for current leaks. (See p. 6-7.)
No current leaks
Measure the charging voltage between the battery terminals.
(See p. 6-7.)
Accessories are installed
Current leaks
• Remove accessories.
• Short circuit of the wire harness.
• Loose or disconnected wires.
• Faulty battery.
• Faulty battery.
• Abnormal driving condition.
Correct
Incorrect
Measure the continuity of the stator coil. (See p. 6-8. )
Continuity
Inspect generator no-load voltage. (See p. 6-8. )
Good
Inspect regulator/ rectifier.
(See p. 6-9.)
Good
Inspect the wirings.
Good
Others
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No continuity
• Faulty stator coils or disconnected coupler.
No good
No good
• Faulty generator rotor or stator coil.
• Faulty regulator/rectifier.
-No good-
• Short circuit of wire harness.
• Poor contact of couplers.
• Faulty battery.
Battery overcharges • Faulty regulator/rectifier
• Faulty battery
• Poor contact of stator coil coupler
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6-7 ELECTRICAL SYSTEM
INSPECTION
BATTERY LEAK CURRENT INSPECTION
• Remove the front seat and right frame cover. (See p.
5-1.)
• Turn the ignition switch to the OFF position.
• Disconnect the battery lead wire.
• Connect the tester between the battery terminal and the battery lead wire.
NOTE:
Leakage is evident if the reading is over 1mA.
Battery current leak: Under 1mA
A CAUTION
* Because the current leak might be large, turn the tester to the high range first to avoid te ster damage. * Do not turn the ignition switch to the "ON" position when measuring the current.
When checking to find the excessive current leak, remove the couplers and connectors, one by one, checking each part.
CHARGING OUTPUT INSPECTION
• Remove the front seat and right frame cover. (See p.
5-1.)
• Start the engine, turn the lighting switch to ON and the dimmer switch to HI, and run the engine at 5 000 r/min.
Measure the DC voltage between the and battery terminals with a tester. If the tester reads under 13.5V or over 15.0V, inspect the stator coil and regulator/rectifier.
A CAUTION
If the tester is set for current or re sistance readings and voltage is applied across the test probe s, damage will result. Therefore, it is important that the tester knob on the tester be set to the proper position before making any measurements.
NOTE:
When mak ing this test, be sure that the battery is fullycharged.
Charging output
Standard: 13.5-15.0V at 5 000 r/min.
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STATOR COIL RESISTANCE
• Remove the front seat. (See p. 5-1.)
• Remove the fuel tank. (See p. 4-1.)
• Disconnect the stator coil coupler.
Measure the resistance between the three lead wires using a tester.
Also check that the stator core is insulated.
If the resistance is incorrect, replace the stator coil with a new one.
Stator coil resistance:
GENERATOR NO-LOAD PERFORMANCE INSPECTION
• Remove the front seat. (See p. 5-1.)
• Remove the fuel tank. (See p. 4-1.)
• Disconnect the stator coil coupler.
• Start the engine and keep it running at 5 000 r/min.
Measure the voltage between the three lead wires using a tester.
If the tester reads under the specified value, replace the stator coil and pick-up coil, or the generator rotor with a new one.
Generator no-load performance:
More than 60V (AC) at 5 000 r/min
(When engine is cold)
ELECTRICAL SYSTEM 6-8
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6-9 ELECTRICAL SYSTEM
REGULATOR/RECTIFIER
• Remove the front seat. (See p. 5-1.)
• Remove the fuel tank. (See p. 4-1.)
• Disconnect the regulator/rectifier couplers.
Measure the voltage between the lead wires in the following table.
09900-25008: Multi circuit tester set
Tester knob indication: Diode test
Unit: V
R
R
B/W 1.2-1.5
Probe of tester to:
B/W Y
2
0.5-1.0
0.3-0. 7 0.3-0.7
1.2-1.5
1.2-1.5
1.2-1.5
0.3-0. 7
1.2-1.5
0.3-0. 7 1.2-1.5
1.2-1.5
1.2-1.5
0.3-0. 7
1.2-1.5
1.2-1.5
Y
3
0.3-0. 7
1.2-1.5
1.2-1. 5
1.2-1.5
NOTE:
If the tester lead under 1.4V, replace the battery of multi circuit tester when do not connecting the tester probes.
WIRE COLOR
R: Red
Y: Yellow
B/W: Black with White tracer
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ELECTRICAL SYSTEM 6-10
STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM
STARTER SYSTEM DESCRIPTION
The start er system consists of the following components: the start er motor, starter relay, clutch lever position s witch, side-stand relay, side-stand s witch, neutral switch, starter button, engine stop switch, ignition switch and battery. Pressing the starter button (on the right handlebar switch) energizes the starter relay, causing the contact points to close, thus completing the circuit from the starter motor to the battery.
The starter motor draws about 80 amperes to start the engine.
Starter motor
Clutch lever position sw itch
Engine stop sw itch
Ignition sw itch
Fuse
Neutral sw itch
Starter relay
Starter button
Side-stand relay
Side-stand sw itch
SIDE-STAND/IGNITION INTERLOCK SYSTEM DESCRIPTION
This side-stand/ignition interlock system prevents the motorcycle from being started with the sidestand down. The system is operated by an electric circuit provided between the battery and ignition coil.
Fuse Ignition sw itch
Side-stand relay
Engine stop sw itch
To ignitor and ignition coil
Neutral indicator light
Battery
Neutral sw itch
Side-stand sw itch
WIRE COLOR
G : Green
R : Red
Bl : Blue
O : Orange
0/B : Orange w ith Black tracer
O/W: Orange w ith White tracer
O/Y : Orange w ith Yellow tracer
Bl/B: Blue w ith Black tracer
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6-11 ELECTRICAL SYSTEM
TROUBLESHOOTING
Starter motor will not run.
The transmission is in neutral. Grasp the clutch lever. Turn on the ignition switch with the engine stop switch in
"RUN" position. Listen for a click from the starter relay when the starter button is pushed.
No click
Clicks
Check if the starter motor runs when its terminal is connected to the battery terminal. (Do not use a thin "wire" because a large amount of current flows.)
Run Does not run
• Faulty starter motor
• Faulty starter relay
• Loosen or disconnected starter motor lead wire
Measure the starter relay voltage at the starter relay connectors (between Y/B and B/W ) when the starter button is pushed.
Voltage
No voltage • Faulty ignition switch
• Faulty engine stop switch
• Faulty clutch lever position switch
• Faulty neutral switch
• Faulty side-stand relay
• Faulty starter button
• Poor contact of connector
• Open circuit in wire harness
Check the starter relay.
(See pp. 6-14 and -15.)
OK
No good
• Faulty starter relay
• Poor contact of the starter relay
The starter motor runs when the transmission is in neutral, but does not run when the transmissi on is in any position other than neutral, with the side-stand up.
Check the side-stand switch.
(See pp. 6-15 and -16.)
OK
No good
• Faulty side-stand switch
• Open circuit in wire harness
• Poor contact of connector
Others
Engine does not turn though
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• Faulty starter clutch
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STARTER MOTOR REMOVAL AND
DISASSEMBLY
• Disconnect the starter motor lead wire.
• Remove the starter motor.
• Disassemble the starter motor, as shown in the illustration.
ELECTRICAL SYSTEM 6-12
Housing end (Outside)
O-ring
Brush spring
Brush holder
Starter motor case
Armature
O-ring
Housing end (Inside)
O-ring
O-ring (2 pcs)
Oil seal
STARTER MOTOR INSPECTION
CARBON BRUSH
Inspect the brushes for abnormal wear, crack or smoothness in the brush holder.
If either carbon brush is defective, replace the brush assembly.
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6-13 ELECTRICAL SYSTEM
COMMUTATOR
Inspect the commutator for discoloration, abnormal wear or undercut
If the commutator is abnormally worn, replace the armature.
If the commutator surface is discolored, polish it with #400 sandpaper and wipe it using a clean, dry cloth. If there is no undercut, scrape out the insulator with a saw blade.
ARMATURE COIL INSPECTION
Measure for continuity between each segment. Measure for continuity between each segment and the armature shaft.
If there is no continuity between the segments or there is continuity between the segments and shaft, replace the armature with a new one.
OIL SEAL INSPECTION
Check the seal lip for damage or leakage.
If any damage is found, replace the housing end (inside).
STARTER MOTOR REASSEMBLY
Reassemble the starter motor in the reverse order of disassembly. Pay attention to the following points:
A CAUTION
Replace the O-rings with new ones to prevent oil leakage and moisture.
• Apply SUZUKI SUPER GREASE "A" to the lip of the oil seal.
99000-25010: SUZUKI SUPER GREASE "A"
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ELECTRICAL SYSTEM 6-14
• Apply a small quantity of SUZUKI MOLY PASTE to the armat ure shaft.
99000-25140: SUZUKI MOLY PASTE
• Apply SUZUKI SUPER GREASE "A" to the O-rings.
99000-25010: SUZUKI SUPER GREASE "A"
• Apply a small quantity of THREAD LOCK "1342" to the starter motor housing bolts.
99000-32050: THREAD LOCK "1342"
STARTER RELAY INSPECTION
• Remove the front seat and right frame cover. (See p.
5-1.)
• Disconnect the battery lead wire
• Remove the starter relay cover
• Disconnect the starter motor lead wires and starter relay lead wire coupler
• Remove the starter relay.
Apply 12 volts to terminals and , and measure for continuity between the positive and negative terminals. If the starter relay clicks and continuity is found, the relay is ok.
09900-25008: Multi circuit tester set
Tester knob indication: Continuity test (•))) )
A CAUTION
Do not apply battery voltage to the starter relay for more than five secondes.
This may overheat and damage the relay coil.
To starter motor To battery
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6-15 ELECTRICAL SYSTEM
Measure the starter relay resistance between the terminals
( and ).
Starter relay resistance: 3-6
SIDE-STAND/IGNITION INTERLOCK
SYSTEM PART INSPECTION
If the interlock system does not operate properly, check each component. If any abnormality is found, replace the component with a new one.
NEUTRAL SWITCH
The neutral switch coupler is located under the fuel tank.
• Remove the front seat. (See p. 5-1.)
• Remove the fuel tank. (See p. 4-1.)
• Disconnect the neutral switch coupler and measure the continuity between Blue and Ground with the transmission in neutral.
Blue Ground
ON (in neutral)
OFF (not in neutral)
SIDE-STAND SWITCH
The side-stand switch coupler is located under the fuel tank.
• Remove the front seat. (See p. 5-1.)
• Remove the fuel tank. (See p. 4-1.)
• Disconnect the side-stand switch lead wire coupler and measure the voltage between Green and Black/White lead wires.
09900-25008: Multi circuit tester set Tester knob indication: Diode test ( )
Green
( Probe)
Black/White
( Probe)
0.4-0. 6 V ON (UPright position)
OFF
(DOW N position)
1.4-1. 5 V
NOTE:
If the tester read under 1.4V, replace the battery of multi circuit tester when do not connecting the tester probes.
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TURN SIGNAL/SIDE-STAND RELAY
The turn signal relay is corporated with the side-stand relay and diode to form the one component part which is called the turn signal/side-stand relay. It is located under the luggage box.
• Remove the front seat. (See p. 5-1.)
• Remove the luggage box
SIDE-STAND RELAY INSPECTION
First check the insulation between and terminals with tester. Then apply 12 volts to and terminals, to and to , and check the continuity between and . If there is no continuity, replace turn signal/side-stand relay with a new one.
ELECTRICAL SYSTEM 6-16
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6-17 ELECTRICAL SYSTEM
DIODE INSPECTION
Using multi circuit tester, measure the voltage between the terminals in the following table.
Unit: V
Probe of tester to:
,
1.4-1.5
i
0.4-0.6
09900-25008: Multi circuit te ster set Tester knob indication: Diode te st
NOTE:
If the tester read under 1.4V, replace the battery of multi circuit tester when do not connecting the tester probes.
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ELECTRICAL SYSTEM 6- 18
IGNITION SYSTEM (DIGITAL IGNITOR)
DESCRIPTION
The fully transistorized ignition system consists of the following components: a generator, ignitor, ignition coil and spark plug. The ignition timing is programmed and stored in the ignitor. The pick-up coil is mounted in the generator. The induced signal in the pick-up coil is sent to the wave-form arrangement circuit and the CPU receives this signal and calculates the best ignition timing. The CPU outputs the signal to the transistor of the ignition coil output circuit which is connected to the primary windings of the ignition coil which is turned "off" and "on" accordingly. Thus, it induces the secondary current in the ignition coil's secondary winding and produces the spark between the spark plug gap.
Pick-up coil
Ignitor
Wave foam arrangement circuit
Ignitor pow er source circuit
Transistor
CPU
(Central
Processing
Unit)
Engine stop sw itch
Side-stand relay
Fuse
Ignition coil
Spark plug
Ignition sw itch
Main fuse
Battery
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6-19 ELECTRICAL SYSTEM
TROUBLESHOOTING
No spark or poor spark
Check the ignition system couplers for poor connections.
Correct
* Check that the transmission is in neutral and the en gine stop switch is in the "RUN" position. Grasp the clutch lever. Check that the fuse is not blown and the battery is fully-charged before diagnosing.
Looseness • Poor connection of couplers
Measure the battery voltage between in put
Incorrect
Correct lead wires (O/W and B/W) at the igni ter with the ignition switch in the "ON" position.
Measure the ignition coil primary peak voltage. (See p. 6-
20.)
NOTE: The ignition coil peak voltage inspection method is applicable only with
Incorrect
Correct
Incorrect the multi circuit tester and the peak volt adaptor.
Inspect the ignition coil.
(See p. 6-21. )
• Faulty ignition switch
• Faulty turn signal/side-stand relay
• Faulty engine stop switch
• Broken wire harness or poor connection of related circuit couplers
Inspect the spark plug. (See p p. 2-4 and -5.)
Incorrect
Correct
• Faulty igniter unit
• Faulty spark plug
Incorrect
• Poor conne ction of the spark plug cap.
• Faulty ignition coil
Correct
Measure the pick-up coil peak voltage and resistance. (See pp. 6-22 and -23.) NOTE:
Incorrect
• Faulty generator
The pick -up coil peak voltage inspection is applicable only with the multi circuit tester and the peak volt adaptor.
Correct
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• Open circuit in wiring harness
• Poor connection of ignition couplers
ELECTRICAL SYSTEM 6-20
INSPECTION
IGNITION COIL PRIMARY PEAK VOLTAGE
• Remove the front seat. (See p. 5-1.)
• Remove the fuel tank. (See p. 4-1.)
• Disconnect the spark plug cap.
• Connect new spark plug to the spark plug cap and ground it to the cylinder head.
NOTE:
Make sure that the spark plug cap and spark plug is connected properly and the battery Is fully-charged.
Measure ignition coil primary peak voltage in the following procedure.
• Connect the multi circuit tester with the peak volt adaptor as follows.
Probe: White lead wire connector
Probe: Ground
NOTE:
Do not disconnect the ignition coil primary wire.
09900-25008: Multi circuit tester set
A CAUTION
When using the multi circuit tester and peak volt adaptor, refer to the appropriate instruction manual.
• Shift the transmission into neutral, turn the ignition switch to the "ON" position and grasp the clutch lever.
• Press the starter button and allow the engine to crank for a few seconds, and then measure the Ignition coll primary peak voltage.
• Repeat the above procedure a few times and measure the highest ignition coil primary peak voltage.
Tester knob indication: Voltage ( )
Ignition coil primary peak voltage: More than
200 V
AWARNING
While testing, do not touch the tester probes and spark plug to prevent receiving an electric shock.
If the voltage is lower than the standard value, inspect the ignition coil and the pick-up coil. (See pp. 6-21 to -23.)
Ignitor
Peak volt adaptor
Ignition coil
Battery
New spark plug
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6-21 ELECTRICAL SYSTEM
IGNITION COIL RESISTANCE
Measure the ignition coil resistance in both the primary and secondary windings. If the windings are in sound condition, their resistance should be close to the specified values.
Ignition coil resistance
Primary: 3-5 ( terminal- terminal)
Secondary: 17-28 k ( terminal-Spark plug cap)
IGNITOR
• Remove the front seat. (See p. 5-1.)
• Remove the luggage box.
• Remove the ignitor
Measure the voltage between the terminals in the following table.
09900-25008: Multi circuit te ster set Tester knob indication: Diode test ( )
Probe of tester to:
1.2-1.5
1.2-1.5
1.2-1.5
1.2-1.5
1.2-1.5
1.2-1.5
1.2-1.5
1.1-1.5
1.1-1.5
1.2-1.5
1.2-1.5
1.2-1.5
0.9-1.4
1.1-1.5
0.9-1.4
1.1-1.5
0
0
1.1-1.5
1.1-1.5
0.3-0.6
0.3-0.6
1.2-1.5
1.2-1.5
1.2-1.5
1.2-1.5
1.2-1.5
1.2-1.5
1.2-1.5
1.2-1.5
1.2-1.5
1.2-1.5
1.2-1.5
1.2-1.5
1.2-1.5
1.2-1.5
1.2-1.5
1.2-1.5
1.2-1.5
1.2-1.5
1.2-1.5
1.2-1.5
1.0-1.5
1.1-1.5
0.4-0.6
0.4-0.6
1.2-1.5
1.2-1.5
1.2-1.5
1.2-1.5
1.1-1.5
0.5-0.8
0.5-0.8
0.8-1.2
1.2-1.5
1.2-1.5
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ELECTRICAL SYSTEM 6-22
PICK-UP COIL PEAK VOLTAGE
• Remove the front seat. (See p. 5-1.)
• Remove the luggage box.
NOTE:
Be sure that all of the couplers are connected properly and the battery is fully-charged.
• Disconnect the ignitor coupler at the ¡gnitor.
• Measure the pick-up coil peak voltage between the
Green and Blue lead wires on the ignitor coupler.
• Connect the multi circuit tester with the peak volt adaptor as follows.
Probe: Green lead wire
Probe: Blue lead wire
09900-25008: Multi circuit tester set
A CAUTION
When using the multi circuit tester and peak volt adaptor, refer to the appropriate instruction manual.
• Shift the transmission into neutral, turn the ignition switch to the "ON" position and grasp the clutch lever.
• Press the starter button and allow the engine to crank 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.
Tester knob indication: Voltage ( )
Pick-up coil peak voltage: More than 5.0 V (Green-Blue)
If the peak voltage measured on the ignitor coupler is lower than the standard value, measure the peak voltage on the pick-up coil coupler as follows.
Generator
Pick-up coil coupler
Ignitor coupler
Peak volt adaptor
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6-23 ELECTRICAL SYSTEM
• Remove the front seat. (See p. 5-1.)
• Remove the fuel tank. (See p. 4-1.)
• Disconnect the pick-up coil coupler and connect the multi circuit tester with the peak volt adaptor.
Probe: Green lead wire
Probe: Blue lead wire
• Measure the pick-up coil peak voltage in the same man ner as on the ignitor coupler.
Tester knob indication: Voltage
Pick-up coil peak voltage: More than 5.0 V (Green-Blue)
If the peak voltage on the pick-up coil lead wire coupler is ok but on the ignitor coupler is out of specification, the wire harness must be replaced. If both peak voltages are out of specification, the generator must be replaced and rechecked.
PICK-UP COIL RESISTANCE
• Remove the seat and fuel tank and disconnect the pickup coil coupler.
• Measure the resistance between the lead wires and ground. If the resistance is not within the specified value, the generator stator must be replaced.
Pick-up coil resistance: 400-650 (Blue-Green)
(Blue-Ground)
Generator
Generator
Pick-up coil coupler
Pick-up coil coupler
Peak volt adaptor
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SPEEDOMETER
REMOVAL AND DISASSEMBLY
• Remove the speedometer.
• Disassemble the speedometer as follows.
ELECTRICAL SYSTEM 6-24
Speedometer
Speedometer bracket
Speedometer cover
Socket assy.
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6-25 ELECTRICAL SYSTEM
WIRE COLOR
B : Black
Gr : Gray
B/W : Black with White tracer
Bl/B : Blue with Black tracer
Lg : Light green O/G : Orange wit h Green tracer
Y : Yellow
INSPECTION
Check the continuity between lead wires.
If there is no continuity, replace the respective parts.
NOTE:
When checking for continuity, it is not necessary to remove the speedometer.
Bl/B: Neutral
Y: High beam
B: Turn signal (L)
Lg: Turn signal Gr: Illumination
B/W: High beam illumination
Neutral
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LAMPS
HEADLIGHT AND POSITION LIGHT
ELECTRICAL SYSTEM 6-26
Headlight: 12V 60/55W
Position light: 12V 4W ..... Except for E-03, -24, -28 and -33 models
HEADLIGHT BULB REPLACEMENT
• Remove the headlight.
• Disconnect the socket
• Remove the rubber cap
• Remove the bulb by removing the bulb holder spring
• Remove the position light bulb
• Reassemble the bulb in the reverse order of removal.
A CAUTION
If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.
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6-27 ELECTRICAL SYSTEM
BRAKE LIGHT/TAILLIGHT
Brake light/Taillight: 12V 21/5W
BRAKE LIGHT/TAILLIGHT BULB REPLACEMENT
• Remove the rubber cap behind the rear fender.
• Push in on the bulb socket , turn it counterclockwise, and pull it out.
• Remove the brake light/taillight bulb
A CAUTION
If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.
• Reassemble the bulb in the reverse order of removal.
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TURN SIGNAL LIGHTS
ELECTRICAL SYSTEM 6-28
Turn signal light/Running light: 12V 21/5W ..... For E-03, -28 and -33 models
Turn signal light: 12V 21W ..... For the others
TURN SIGNAL LIGHT BULB REPLACEMENT
• Remove the lens by removing the screws.
• Remove the bulb.
CAUTION________________________________
If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.
• Reassemble the bulb in the reverse order of removal.
CAUTION
Do not overtighten the lens fitting screws.
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6-29 ELECTRICAL SYSTEM
RELAYS
STARTER RELAY
The starter relay is located behind the right frame cover.
(See pp. 6-14 and -15.)
TURN SIGNAL/SIDE-STAND RELAY
The turn signal relay is corporated with the side-stand relay and diode to form the one component part which is called the turn signal/side-stand relay. It is located under the luggage box.
• Remove the front seat. (See p. 5-1.)
• Remove the luggage box.
INSPECTION
Before removing the turn signal/side-stand relay, check the operation of the turn signal light.
If the turn signal light does not light, inspect the bulb, turn signal switch and circuit connection.
If the bulb, turn signal switch and circuit connection checked are all right, the turn signal relay may be faulty, replace it with a new one.
NOTE:
Be sure that the battery is full-charged.
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ELECTRICAL SYSTEM 6-30
SWITCHES
Measure eac h switch for continuity using a tester. switch assemblies with new ones.
IGNITION SWITCH
If any abnormality is found, replace the respective
STARTER BUTTON
For E-24
LIGHTING SWITCH
(Except for E-03, -24, -28, -33)
DIMMER SWITCH
PASSING LIGHT SWITCH
(Except for E-03, -28, -33)
TURN SIGNAL SWITCH
ENGINE STOP SWITCH
HORN BUTTON
FRONT BRAKE LIGHT SWITCH
REAR BRAKE LIGHT
SWITCH
CLUTCH LEVER
POSITION SWITCH
WIRE COLOR
B : Black
Br : Brown
Gr : Gray
O : Orange
R : Red
Y : Yellow
W : White Lbl : Light blue
Lg : Light green B/W : Black with
White tracer B/Y : Black with
Yellow tracer B/R : Black with Red tracer O/B : Orange with Black tracer O/BI : Orange with Blue tracer O/R : Orange with Red tracer
O/W : Orange with White tracer O/Y
: Orange with Yellow tracer W/B :
White with Black tracer Y/W :
Yellow with White tracer Y/G :
Yellow with Green tracer
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6-31 ELECTRICAL SYSTEM
BATTERY
SPECIFICATIONS
Type designation
Capacity
Standard electrolyte
S.G.
FTX7L-BS
12V, 21.6 kC(6Ah)/10HR
1.320 at 20°C (68°F)
Upper cover breather
Stopper
Cathode plates
Separator
(fiberglass plate)
Anode plates
Filter
Terminal
Safety valve
INITIAL CHARGING
FILLING ELECTROLYTE
• Remove the aluminum tape which seals the battery filler holes
* Remove the caps from the electrolyte container.
NOTE:
* Do not remove or pierce the sealed areas of the electrolyte container.
* After completely filling the battery with electrolyte, use the caps
from the electrolyte container to seal the battery filler holes.
• Insert the nozzles of the electrolyte container into the battery's electrolyte filler holes. Hold the electrolyte container firmly so that it does not fall. Do not allow any of the electrolyte to spill.
• Make sure that the air bubbles rise to the top of each electrolyte container and leave the electrolyte container in this position for more than 20 minutes.
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NOTE:
If air bubbles do not rise from any one of the filler ports, tap the bottom of the electrolyte container two or three times.
Never remove the electrolyte container from the battery while there is still electrolyte in the container.
• After the electrolyte container is completely empty, remove it from the battery and wait about 20 minutes.
• Insert the caps firmly into the filler holes, so that the top of the caps do not protrude above the upper surface of the battery's top cover.
A CAUTION
* The charging system for a MF battery is different from that of a conventional battery. Only use the specified MF battery.
* Do not remove the caps once they are installed in the battery
ELECTRICAL SYSTEM 6-32
CORRECT
• Measure the battery voltage using a tester. The tester should indicate more than 12.5-12.6V (DC), as shown.
If the battery voltage is lower than specification, charge the battery with a battery charger.
NOTE:
Initial charging for a new battery is recommended if two years have elapsed since the date of manufacture.
SERVICING
Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, clean the battery terminals with sandpaper.
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INCORRECT
6-33 ELECTRICAL
SYSTEM
RECHARGING OPERATION
• Measure the battery voltage using a tester. If the voltage reading is less than 12.0V (DC), recharge the battery with a battery charger.
I A CAUTION ! ________________________
When recharging the battery, remove the battery from the motorcycle.
NOTE:
While recharging, do not remove the caps on the top of the battery.
Recharging time: 0.7A for 5 to 10 hours or 3A for 1 hour
I A CAUTION]
Be careful not to permit the charging current to exceed 3A at any time.
• After recharging, wait at least 30 minutes and then measure the battery voltage using a tester.
• If the battery voltage is less than 12.5V, recharge the battery again.
• If the battery voltage is still less than 12.5V after recharging, replace the battery with a new one.
• When a battery is left unused for a long time, its voltage needs to be regularly measured. When the motorcycle is not used for more than one month (especially during the winter season), measure the battery voltage at least once a month.
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SERVICING INFORMATION
-------------------------------------------
CONTENTS
--------------------------------------------
TROUBLESHOOTING
.................................................................................
7- 1
WIRING DIAGRAM
...................................................................................... 7-
8
WIRE, CABLE AND HOSE ROUTING
........................................................
7-11
FRAME REAR COVER SET-UP
...............................................................
7-19
SPECIAL TOOLS
.........................................................................................
7-20
TIGHTENING TORQUE
...............................................................................
7-23
SERVICE DATA
.........................................................................................
7-26
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7-1 SERVICING INFORMATION
TROUBLESHOOTING
ENGINE
Complaint Symptom and possible causes
Engine will not start, or is hard to start.
s
Compression too low
1. Worn cylinder.
2. Worn piston ring.
3. Worn valve guide or improper valve seating.
4. Loose spark plug.
5. Broken, cracked or damaged piston
6. Slow cranking starter motor.
7. Mistimed valves.
8. Valve clearance out of adjustment.
Spark plug not sparking
1. Damaged spark plug.
2. Damaged spark plug cap.
3. Fouled spark plug.
4. Wet spark plug.
5. Defective ignition coil.
6. Open or short in high-tension cord.
7. Defective pick-up coil or ignitor unit.
No fuel reaching the carburetor
1. Clogged or defective fuel val ve.
2. Defective carburetor needle valve.
3. Clogged fuel hose.
4. Clogged fuel filter.
Engine stalls easily.
1. Fouled spark plug.
2. Defective pick-up coil or ignitor unit.
3. Clogged fuel hose.
4. Clogged carburetor jet.
5. Valve clearance out of adjustment.
Remedy
Rebore or replace.
Replace.
Repair or replace
Tighten.
Replace
See electrical section.
Adjust.
Adjust.
Replace.
Replace.
Clean or replace.
Clean and dry or replace.
Replace.
Replace.
Replace.
Clean or replace. Replace with carburetor needle valve seat. Clean or replace.
Clean or replace.
Clean or replace.
Replace.
Clean.
Clean.
Adjust.
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Complaint
Engine is noisy.
Noisy engine.
Clutch slips.
Clutch drags.
Transmission will not shift.
Symptom and possible causes
Excessive valve chatter
1. Excessive valve clearance.
2. Weak or broken valve spring.
3. Worn cam surface.
4. Worn or burnt camshaft journal. Noise seems to come from the piston
1. Worn piston.
2. Worn cylinder.
3. Carbon build-up in combustion chamber.
4. Worn piston pin or piston pin bore.
5. Worn piston ring or ring groove. Noise seems to come from the cam chain
2. Worn cam chain sprocket.
3. Improperly working cam chain tension adjuster.
Noise seems to come from the clutch
2. Worn clutch hub spline.
3. Worn clutch plate teeth.
4. Distorted clutch plate.
5. Worn clutch release bearing.
6. Weak clutch damper.
7. Weak clutch spring.
Noise seems to come from the crankshaft
2. Worn or burnt crank pin bearing.
3. Worn or burnt ball bearing. Noise seems to come from the transmission
1. Worn or rubbing gear.
2. Worn countershaft spline.
3. Worn driveshaft spline.
4. Worn or rubbing primary gear.
5. Worn bearing.
1. Clutch cable out of adjustment.
2. Weak or broken clutch spring.
3. Worn or distorted clutch pressure plate.
4. Distorted clutch plate.
1. Clutch out of adjustment.
2. Some clutch springs are weak, while others are not.
3. Worn or distorted clutch pressure plate.
4. Distorted clutch plate.
1. Broken gearshift cam.
2. Distorted gearshift fork.
3. Worn gearshift pawl.
SERVICING INFORMATION 7-2
Remedy
Adjust.
Replace.
Replace.
Replace camshaft.
Replace.
Rebore or replace.
Clean.
Replace.
Replace.
Replace cam chain and sprocket.
Replace cam chain and sprocket.
Repair or replace.
Replace countershaft.
Replace clutch hub.
Replace clutch plate.
Replace.
Replace.
Replace primary driven gear.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace countershaft.
Replace driveshaft.
Replace.
Replace.
Adjust.
Replace.
Replace.
Replace.
Adjust.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
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7-3 SERVICING INFORMATION
Complaint
Transmission will not shift back.
Transmission jumps out of gear.
Engine idles poorly.
Symptom and possible causes
1. Broken gearshift shaft return spring.
2. Rubbing or stuck gearshift shaft.
3. Worn or distorted gearshift fork.
1. Worn gear.
2. Worn or distorted gearshift fork.
3. Weakened gearshift cam stopper spring.
4. Worn gearshift pawl.
1. Valve clearance out of adjustment.
2. Improper valve s eating.
3. Worn valve guide.
4. Worn cam surface.
5. Excessive spark plug gap.
6. Defective ignition coil.
7. Defective pick-up coil or ignitor unit.
8. Spark plug too cold.
9. Incorrect float chamber fuel level.
10. Clogged carburetor jet.
11. Defective generator.
Engine runs poorly in high-speed range.
1. Weak valve spring.
2. Worn camshaft.
3. Insufficient spark plug gap.
4. Mistimed valves.
5. Ignition not advanced sufficiently due to poorly working timing advance circuit.
6. Defective ignition coll.
7. Defective pick-up coil or ignitor unit.
8. Low float chamber fuel level.
9. Clogged air cleaner element.
10. Clogged fuel hose, resulting in inadequate fuel supply to carburetor.
Exhaust smoke is dirty or thick.
Engine lacks power.
1. Excessive amount of engine oil.
2. Worn cylinder.
3. Worn piston ring.
4. Worn valve guide.
5. Scored or scuffed cylinder wall.
6. Worn valve stem.
7. Defective val ve stem oil seal.
8. Worn oil ring side rail.
1. Insufficient valve clearance.
2. Weak valve spring.
3. Mistimed valves.
4. Worn cylinder.
5. Worn piston ring.
6. Improper valve seating.
7. Fouled spark plug.
8. Incorrect spark plug.
9. Clogged carburetor jet.
10. Incorrect float chamber fuel level.
11. Clogged air cleaner element.
12. Worn camshaft.
13. Air leaked from intake pipe.
14. Excessive amount of engine oil.
Remedy
Replace.
Repair or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Adjust.
Repair or replace.
Replace.
Replace.
Adjust or replace.
Replace.
Replace.
Replace by hot type plug.
Adjust float height.
Clean.
Replace.
Replace.
Replace.
Regap or replace.
Adjust.
Replace ignitor unit.
Replace. Replace.
Adjust float height.
Clean or replace.
Clean and prime.
Check level and drain.
Rebore or replace.
Replace.
Replace.
Rebore or replace.
Replace valve.
Replace.
Replace oil ring.
Adjust.
Replace.
Adjust.
Rebore or replace.
Replace.
Repair or replace.
Clean or replace.
Replace.
Clean.
Adjust float height.
Clean or replace.
Replace.
Tighten or replace.
Check level and drain.
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SERVICING INFORMATION 7-4
Complaint
Engine overheats.
CARBURETOR
Complaint
Starting difficulty.
Symptom and possible causes
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 incorrect engine oil.
7. Clogged air Intake with dust.
Symptom and possible causes
1. Clogged fuel pipe.
2. Air leaking from joint between starter body and car buretor.
3. Air leaking from carburetor joint.
4. Improperly working starter plunger.
Idling or low-speed trouble.
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.
Remedy
Clean.
Add oil.
Replace or clean.
Adjust.
Retighten or replace.
Change.
Clean.
Remedy
Clean.
Tighten, adjust or replace gasket. Tighten or replace defective parts. Adjust.
Clean or tighten. Tighten or replace defective part.
Clean. Clean. Adjust.
Medium-or high speed trouble.
Overflow and fuel level fluctuations.
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.
Clean. Clean.
Adjust. Clean or replace.
Replace. Replace.
Adjust or replace. Clean or replace with needle valve seat. Adjust float height.
CHASSIS
Complaint
Steering is heavy.
Handlebars wobbles.
Symptom and possible causes
1. Overtightened steering stem nut.
2. Broken bearing/race in steering stem.
3. Distorted steering stem.
4. Low tire pressure.
1. Loss of balance between right and left front fork legs.
2. Distorted front fork.
3. Distorted front axle.
4. Twisted tire.
Remedy
Adjust.
Replace.
Replace.
Regulate.
Adjust or replace.
Repair or replace.
Replace.
Replace.
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7-5 SERVICING INFORMATION
Complaint
Front wheel wobbles.
Rear suspension too soft.
Rear suspension too stiff.
Front suspension too soft.
Front suspension too stiff.
Front suspension too noisy.
Rear wheel wobbles.
Symptom and possible causes
1.
Distorted wheel rim.
2. Worn front wheel bearing.
3. Defective or incorrect tire.
4. Loose front axle.
5. Incorrect front fork oil level.
6. Loose wheel spoke.
1. Weak spring.
2. Insufficient fork oil.
1. Excessively viscous fork oil.
2. Excessive fork oil.
1. Insufficient fork oil.
2. Loose front suspension fastener.
1. Distorted wheel rim.
2. Worn rear wheel bearing.
3. Defective or incorrect tire.
4. Worn swingarm bearing.
5. Loose rear axle nut or swingarm pivot nut.
6. Loosen wheel spokes.
7. Loosen rear suspension fastener.
1. Weak rear shock absorber spring.
2. Rear shock absorber leaks oil.
3. Improper suspension setting.
1. Improperly adjusted rear suspension.
2. Bent swingarm.
3. Worn swingarm and rear suspension related bearings.
1. Loose rear suspension fastener.
2. Worn swingarm bearing.
Rear suspension too noisy.
BRAKES
Complaint
Brake power insufficient.
Symptom and possible causes
1. Leakage of brake fluid.
2. Worn brake pad.
3. Oil in brake pad surface.
4. Worn brake disc.
5. Air in h ydraulic system.
6. Worn brake shoe.
7. Oil in brake shoe surfaces.
8. Excessively worn brake drum.
9. Excessive brake pedal play.
Remedy
Replace.
Replace.
Replace.
Tighten.
Adjust.
Tighten.
Replace.
Check level and add.
Replace.
Check level and drain.
Check level and add.
Tighten.
Replace.
Replace.
Replace.
Replace.
Tighten.
Tighten.
Tighten.
Replace.
Replace.
Adjust.
Adjust.
Replace.
Replace.
Tighten.
Replace.
Remedy
Repair or replace.
Replace.
Clean brake disc and brake pads.
Replace.
Bleed.
Replace.
Clean.
Replace.
Adjust.
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Complaint
Brake squeaks.
Symptom and possible causes
1. Carbon adhesion on brake pad surface.
2. Tilted brake pad.
3. Damaged wheel bearing.
4. Worn brake pad.
5. Foreign material in brake fluid.
6. Clogged return port of master cylinder.
7. Brake shoe surface glazed.
8. Worn brake shoe.
9. Loose front axle or rear axle nut.
SERVICING INFORMATION 7-6
Remedy
Clean surface with sandpaper.
Readjust brake pad position or replace. Replace.
Replace.
Change brake fluid.
Disassemble and clean master cylinder. Clean surface with sandpaper.
Replace. Tighten.
Brake lever or pedal stroke excessive.
1. Air in hydraulic system.
2. Insufficient brake fluid.
3. Incorrect brake fluid.
4. Worn brake camshaft.
5. Excessively worn brake shoes and/or brake drum.
Brake fluid leaks.
1. Loose connection joint.
2. Cracked brake hose.
3. Worn piston seal.
ELECTRICAL
Complaint
No sparking or poor sparking.
Spark plug is wet or quickly becomes fouled with carbon.
Symptom and possible causes
1. Defective ignition coil.
2. Defective spark plug.
3. Defective pick-up coil.
1. Defective ignitor unit.
1. Excessively rich air/fuel mixture.
2. Excessively high idling speed.
3. Incorrect gasoline.
4. Clogged air cleaner element.
5. Incorrect spark plug (cold type).
Spark plug quickly becomes fouled with oil or carbon.
Spark plug electrodes overheat or burn.
1. Worn piston ring.
2. Worn piston.
3. Worn cylinder.
4. Excessive val ve-stem-to-valve-guide clearance.
5. Worn valve stem oil seal.
1. Incorrect spark plug (hot type).
2. Overheated engine.
3. Loose spark plug.
4. Excessively lean air/fuel mixture.
Generator does not charge.
1. Open or short in lead wires, or loose lead connec tions.
2. Shorted, grounded or open stator coil.
3. Shorted or panctured regulator/rectifier.
Bleed.
Check level and add.
Bleed any air.
Change.
Replace.
Replace.
Tighten.
Replace.
Replace
Remedy
Replace.
Replace.
Replace.
Replace.
Adjust carburetor
Adjust carburetor
Change.
Clean or replace.
Change to hot type spark plug.
Replace.
Replace.
Rebore or replace.
Replace.
Replace.
Change to cold type spark plug.
Tune-up.
Tighten.
Adjust carburetor.
Repair, replace or connect properly.
Replace. Replace.
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7-7 SERVICING INFORMATION
Complaint
Generator charges but charging rate is below the specification.
Generator overcharges.
Unstable charging.
Starter button does not work.
Symptom and possible causes
1. Lead wires tend to get shorted or open-circuited or loosely connected at terminal.
2. Grounded or open-circuited stator coils or genera tor.
3. Defective regulator/rectifier.
4. Defective battery cell plates.
1. Internal short-circuit in the battery.
2. Damaged or defective regulator/rectifier.
3. Poorly grounded regulator/rectifier.
1. Lead wire insulation frayed due to vibration, resulting in intermittent shorting.
2. Internally shorted generator.
3. Defective regulator/rectifier.
1. Run down battery.
2. Defective switch contact.
3. Brushes do not seat properly on the commutator in the starter motor.
4. Defective starter relay.
Remedy
Repair or tighten.
Replace.
Replace. Replace battery.
Replace battery.
Replace.
Clean, repair or replace.
Repair or replace.
Replace. Replace.
Recharge or replace.
Replace.
Repair or replace.
Replace.
BATTERY
Complaint
Sulfation or spots on surfaces of cell plates.
Battery runs down quickly.
Symptom and possible causes
1. Cracked battery case.
2. Battery has been left In a run-down condition for a long time.
1. Incorrect charging method.
2. Battery cell plates have lost much of their active ma terial as a result of overcharging.
3. Internally shorted battery.
4. Excessively low battery voltage.
5. Battery is too old.
Remedy
Replace battery.
Replace.
Check generator or regulator/rectifier circuit connections, and make necessary adjustment to obtain specified charging operation.
Replace battery and correct charging system. Replace.
Recharge Replace.
Battery sulfation.
1. Incorrect charging rate.
(When not in use, the battery should be checked at least once a month and properly charged if necessary, to a void sulfation.)
2. The battery was left unused in a cold climate for too long.
Replace battery.
Replace battery if badly sulfated.
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WIRING DIAGRAM
FOR E-03, -28 and -33
SERVICING INFORMATION 7-8
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7-9 SERVICING INFORMATION
FOR E-24
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FOR THE OTHERS
SERVICING INFORMATION 7-10
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Pass through the w iring harness right side of the clutch cable, speedometer cable and brake hose.
Wiring harness
Starter motor
Clamp
Clamp
Starter motor lead w ire
Clamp
Clamp
Handlebar sw itch (L&R)
Handlebar sw itch (L&R)
Starter motor
Clamp
Wiring harness
Air cleaner
Generator
Neutral sw itch
Side-stand sw itch
Clamp
Side-stand sw itch Clamp
Regulator/rectifier
Neutral sw itch
Side-stand sw itch
Clamp
Wiring harness
Clamp
Brake light/Taillight
Rear turn signal light (L)
Clamp
Rear fender
Turn signal/side-stand relay
Ignitor
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Clamp Clamp
Wiring harness
Clamp
Handlebar switch (L&R)
Clamp
Starter motor
Starter motor
Wiring harness
Generator
Wiring harness
Clamp
Rear turn signal light (R)
Battery
Battery terminal
Wiring harness
High tension cord
(Ignition coil)
Handlebar switch
(L&R) ________
Clamp
Clamp
Pass through the handlebar switch (R) lead wire under the brake hose.
Clamp
Rear turn signal light (L)
Brake light/Taillight
Starter relay
Rear brake sw itch
Clamp
Engine ground
Starter motor
Starter motor
Clamp
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7-13 SERVICING INFORMATION
Generator rolor
Pick-up coil
Generator lead w ire
Neutral sw itch
Clamp
Engine ground w ire
Side-stand sw itch lead w ire
Clamp
Neutral switch lead wire
Side-stand sw itch lead w ire
Neutral sw itch lead w ire
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Stator coil
SERVICING INFORMATION 7-14
CABLE ROUTING
Clamp cable)
\
Throttle cable (returning
Throttle cable (pulling cable)
Clamp
Clamp
Throttle cables
Clamp
Clamp
Handlebar sw itch (R)
Wiring harness
Throttle cable (pulling cable) Throttle cable (returning cable)
Brake hose
Throttle cables
Brake hose
Clamp
Throttle cables
Starter cable
Clutch cable
Starter cable
Pass the throttle cables outside of the brake hose.
Clamp
Wiring harness
Clutch cable
Starter cable
Starter cable
Clamp
Clamp
Clamp
Clamp
Clutch cable
Starter cable
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7-15 SERVICING INFORMATION
Brake hose
Guide
Speedometer cable
Pass the speedometer cable outside of the brake hose.
Clamp
100 mm (4.0 in)
Caliper rubber bushing
Guide
Ma x. 10 mm (0.4 in) 4 Do not contact the guide to the caliper rubber bushing.
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SERVICING INFORMATION 7-16
Rear brake switch cable
Clamp
Seat lock cable
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Rear brake cable clip
Clamp
Rear brake cable
Clamp
Rear brake cable
Clamp
Rear brake switch cable
7-17 SERVICING INFORMATION
FRONT BRAKE HOSE ROUTING
Clamp
Master cylinder
Master cylinder
Clamp
/ Clamp the brake \
\ hose securely. /
Brake hose
Clamp
Speedometer cable
Clamp
/ Clamp the brake \
\ hose securely. /
Brake caliper
After touching the brake hose union to the stopper, tighten the union bolt to the specified torque.
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Stopper
SERVICING INFORMATION 7-18
CARBURETOR HOSE ROUTING
Right Left
Left
(Engine side) (Air cleaner side)
Carburetor clamp position
Right
Air cleaner
Carburetor
Carburetor air vent hose
Clamp
Air cleaner drain hose
Battery case
Carburetor overflow hose
VIEW A
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7-19 SERVICING INFORMATION
FRAME REAR COVER SET-UP
Rear fender
Frame rear cover
Spacer
Frame
Rear fender brace
Cushion
Nut
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SERVICING INFORMATION 7-20
SPECIAL TOOLS
09900-00401
"L" type hexagon w rench set
09900-00410 Hexagon w rench set
09900-06107
Snap ring pliers
09900-06108
Snap ring pliers
09900-09004
Impact driver set
09900-20101
Vernier calipers
(150 mm)
09900-20202
Micrometer
(25-50 mm)
09900-20203
Micrometer
(50-75 mm)
09900-20205
Micrometer
(0-25 mm)
09900-20508
Cylinder gauge set
09900-20605
Dial calipers
09900-20606
Dial gauge
(1/100 mm, 10 mm)
09900-20701
Magnetic stand
09900-20803
Thickness gauge
09900-20805 Tire depth gauge
09900-21304
V-block set
(100 mm)
09900-22301
09900-22302
Plastigauge
09900-22401
09900-22403 Small bore gauge
09900-25008 Multi circuit tester set 09900-26006
Tachometer
09910-20116
Conrod holder
09910-32812
Crankshaft installer
09910-32840
Attachment
09910-34510
Piston pin puller
09913-50121 Oil seal remover
09913-75510
Bearing installer
09913-75520
Bearing installer
09913-75830
Bearing installer
09913-76010
Bearing installer
09913-84510
Bearing installer
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7-21 SERVICING INFORMATION
09913-85210
Bearing installer
09915-64510
Compression gauge
09915-74510
Oil pressure gauge
09916-14510
Valve lifter
09916-14910 Valve lifter attachment
09916-21111
Valve seat cutter set See p. 3-28.
09916-24450
Solid pilot (N-
100-5.52)
09916-34542 Valve guide reamer handle
09916-34550 Valve guide reamer (5.5 mm)
09916-34561
Valve guide reamer
(11.3 mm)
09916-44910
Valve guide remover/ installer
09916-84511
Tw eezers
09917-14920
Valve adjuster w rench
09918-03810
Adaptor
09920-13120
Crankcase separator
09920-53740 Clutch sleeve hub holder 09923-74510
Bearing remover
09924-84510 Bearing installer set
09924-84521 Bearing installer set
09930-10121 Spark plug socket w rench set 09930-11920
Torx bit JT40H
09930-11940
Bit holder
09930-30102
Sliding shaft
09930-34960
Rotor remover
09930-44913
Rotor holder
09940-14911
Steering stem nut w rench
09940-52880 Front fork oil seal installer set
09940-60113
Spoke nipple w rench
09941-34513 Steering outer race installer
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SERVICING INFORMATION 7-22
09941-50111
Bearing remover
09941-54911
Bearing outer race remover
09941-74910
Steering bearing installer
09943-74111 Front fork oil level gauge
NOTE:
When ordering a special tool, please confirm whether it is available or not.
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CHASSIS
ITEM
Handlebar clamp bolt
Handlebar holder nut
Steering stem head bolt
Front fork upper clamp bolt
Front fork lower clamp bolt
Front fork cap bolt
Front fork damper rod bolt
Front axle
Front axle pinch bolt
Front brake caliper mounting bolt
Front brake pad mounting bolt
Front brake hose union bolt
Front brake caliper air bleeder valve
Front brake master cylinder mounting bolt
Front brake disc bolt
Front footre st bolt
Swingarm pivot nut
Rear axle nut
Rear torque link nut (front and rear)
E-03,
-28, -33
The others
Rear shock absorber mounting bolt or nut
Rear sprocket nut
Rear brake cam lever nut
Spoke nipple
10
23
26
72
65
78
13
29
50
10
4.5
39
18
23
7.5
N-m
16
45
65
23
33
23
20
65
23 kg-m
1.6
4.5
6.5
2.3
3.3
2.3
2.0
6.5
2.3
3.9
1.8
2.3
0.75
1.0
2.3
2.6
7.2
6.5
7.8
1.3
2.9
5.0
1.0
0.45
SERVICING INFORMATION 7-24
28.0
19.0
52.0
47.0
56.5
9.5
13.0
16.5
5.5
7.0
16.5
21.0
36.0
7.0
3.5
Ib-ft
11.5
32.5
47.0
16.5
24.0
16.5
14.5
47.0
16.5
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7-25 SERVICING INFORMATION
TIGHTENING TORQUE CHART
For other bolts and nuts listed previously, refer to this chart:
Bolt Diameter
(mm)
4
5
6
8
10
12
14
16
18
Conventional or
"4" marked bolt
N-m kg-m Ib-ft
1.5
3
0.15
0.3
1.0
2.0
6
13
29
45
65
105
160
0.6
1.3
2.9
4.5
6.5
10.5
16.0
4.5
9.5
21.0
32.5
47.0
76.0
115.5
N-m
2
5
10
23
50
85
135
210
240
"7" marked bolt kg-m
0.2
0.5
1.0
2.3
5.0
8.5
13.5
21.0
24.0
Ib-ft
1.5
3.5
7.0
16.5
36.0
61.5
97.5
152.0
173.5
Conventional bolt "4" marked bolt "7" marked bolt
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SERVICE DATA
VALVE + GUIDE
Valve diam.
ITEM
Valve clearance (when cold)
Valve guide to valve stem clearance
Valve stem deflection
Valve guide I.D.
Valve stem O.D.
Valve stem runout
Valve head thickness
Valve stem end length
Valve seat width
Valve head radial runout
Valve spring free length
Valve spring tension
SERVICING INFORMATION 7-26
IN.
E X.
IN.
E X.
IN.
E X.
STA NDA RD
26
(1.0)
22
(0.9)
0.03-0.08
(0.001 -0. 003)
0.08-0.13
(0.003-0.005)
0.025-0.052
(0.0010-0.0020)
0.040-0.067
(0.0016-0.0026)
IN. & E X.
IN. & E X.
IN.
E X.
5.500-5.512
(0.2165-0.2170)
5.460-5.475
(0.2150-0.2156)
5.445-5.460
(0.2144-0.2150)
IN. & E X.
IN. & E X.
IN. & E X.
IN. & E X. 0.9-1. 1
(0.035-0.043)
IN. & E X.
IN. & E X.
IN. & E X. 18.4-21.6 kg
(40.56-47.62 lbs) at length 35.0 mm (1.38 in)
Unit: mm (in)
LIMIT
0.35
(0.014)
0.05
(0.002)
0.5
(0.02)
3.6
(0.14)
0.03
(0.001)
40.1
(1.58)
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7-27 SERVICING INFORMATION
CAMSHAFT + CYLINDER HEAD
Cam height
ITEM
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
Camshaft runout
Rocker arm I. D.
Rocker arm shaft O.D.
IN.
E X.
R. side
L. side
R. side
L. side
IN. & E X.
IN. & E X.
IN. & E X.
STANDARD
34.990-35.040
(1.3776-1.3795)
35.030-35.080
(1.3791-1.3811)
0.032-0.066
(0.0013-0.0026)
25.012-25.025
(0.9847-0.9852)
20.012-20.025
(0.7879-0.7884)
24.959-24.980
(0.9826-0.9835)
19.959-19.980
(0.7858-0.7866)
12.000-12.018
(0.4724-0.4731)
11.966-11.984
(0.4711-0.4718)
Cylinder head distortion
Cylinder head cover distortion
CYLINDER + PISTON + PISTON RING
Cylinder bore
Piston diam.
ITEM
Compression pressure
Piston to cylinder clearance
STA NDA RD
1 000-1 400 kPa
/10.0-14.0 kg/cm
2
\
[
142-199 psi
)
0.045-0.055
(0.0018-0.0022)
72.000-72.015
(2.8346-2.8352)
71.950-71.965
(2.8327-2.8333)
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion
Piston ring free end gap 1st N
Approx.
2nd N
Approx.
Piston ring end gap 1st
2nd
0.10-0.30
(0.004-0.012)
0.10-0.30
(0.004-0.012)
Piston ring to groove clearance 1st
9nH c.\\\
Unit: mm (in)
LIMIT
34.690
(1.3657)
34.730
(1.3673)
0.150
(0.0059)
0.10
(0.004)
0.05
(0.002)
0.05
(0.002)
Unit: mm (in)
LIMIT
800 kPa / 8 kg/cm
2
\
{
114 psi j
0.120
(0.0047)
72.085
(2.8380)
71.880
(2.8299)
0.05
(0.002)
7.6
(0.30)
8.8
(0.35)
0.50
(0.020)
0.50
(0.020)
0.180
(0.0071)
0.150
(0.0059)
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SERVICING INFORMATION 7-28
LIMIT ITEM
Piston ring groove width
Piston ring thickness
1st
2nd
Oil
1st
2nd
STANDARD
1.01-1.03
(0.040-0.041)
1.21-1.23
(0.047-0.048)
2.51-2.53
(0.099-0.100)
0.975-0.990
(0.0384-0.0390)
1.170-1.190
(0.0461 -0.0469)
18.002-18.008
(0.7087-0.7090)
17.992-18.000
(0.7083-0.7087)
Piston pin bore
Piston pin O.D.
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crankshaft web to web widt h
Crankshaft runout
Balancer spring free length
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60°C, 140°F)
STANDARD
18.006-18.014
(0.7089-0.7092)
0.10-0.65
(0.004-0.026)
20.95-21.00
(0.825-0.827)
60.0 + 0.1
(2.362 ± 0.004)
STANDARD
2.812(68/21 x 33/38)
Above 30 kPa (0.3 kg/cm
2
, 4.3 psi)
Below 70 kPa (0.7 kg/cm
2
, 10.0 psi) at 3 000 r/min.
CLUTCH
ITEM
Clutch cable play
Clutch release screw
Drive plate thickness
Drive plate claw width
Driven plate distortion
Clutch spring free lengt h
No.1
No.2
STA NDA RD
10-15
(0.4-0.6)
turn back
2.92-3.08
(0.115-0.121)
3.45-3.55
(0.136-0.140)
15.9-16.0
(0.626-0.630)
18.030
(0.7098)
17.980
(0.7079)
Unit: mm (in)
LIMIT
18.040
(0.7102)
3.0
(0.12)
1.0
(0.04)
0.05
(0.002)
10.0
(0.39)
LIMIT
Unit: mm (in)
LIMIT
2.62
(0.103)
3.15
(0.124)
15.0
(0.590)
0.10
(0.004)
40.9
(1.61)
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7-29 SERVICING INFORMATION
TRANSMISSION + DRIVE CHAIN
Primary reduction ratio
Final reduction ratio
Gear ratios Low
2nd
3rd
4th
Top
Shift fork to groove clearanc e
Shift fork groove width
Shift fork thickness
Drive chain
ITEM
Drive chain slack
STANDARD
3.238(68/21)
2.733(41/15)
2.636(29/11)
1.687(27/16)
Type
Links
20-pitch lengt h
1.263(24/19)
1.000(20/20)
0.818(18/22)
0.20-0.40
(0.008-0.016)
4.25-4.35
(0.167-0.171)
3.95-4.05
(0.156-0.159)
DID520V C5
110
5-15
(0.2-0.6)
CARBURETOR
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.)
Pilot air jet No. 1 (P.A.J.1)
Pilot air jet No.2 (P.A.J.2)
Throttle valve (Th.V.)
Pilot screw (PS.)
Throttle cable play
Starter plunger cable play
SPECIFICATION
E-01,02, 04, 25, 34 E-17, 22, 24
MIKUNI BSR32SS
32 mm
13F0 13F2
1 300 ± 100 r/min.
13.0 ±0. 5 mm
#115
5C60-3rd
P-0
#17.5
#87.5
#140
#110
2Vá turns out
2-4 mm (0.08-0.16 in)
0.5-1. 0 mm (0.02-0. 04 in)
turns out
Unit: mm (in) Except ratio
LIMIT
0.60
(0.024)
319.4
(12.57)
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SERVICING INFORMATION 7-30
CARBURETOR
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.)
Pilot air jet No. 1 (P.A.J.1)
Pilot air jet No.2 (P.A.J.2)
Throttle valve (Th.V.)
Pilot screw (PS.)
Throttle cable play
Starter plunger cable play
SPECIFICATION
E-03, 28
MIKUNI BSR32SS
32 mm
13F3
1 300 ± 50 r/min.
13.0
± 0. 5 mm
5C65
#87.5
#120
#110
PRE-SE T
2-4 mm
(0.08-0.16 in)
0.5-1. 0 mm (0.02-0. 04 in)
E-33
13F4
ELECTRICAL_________________________________________________ Unit: mm (in)
ITEM SPECIFICATION NOTE
Ignition timing
Spark plug
Spark performance
Ignition coil resistance
Type
10°B. T.D. C. at1 300r/min.
NGK:
DR8EA
DENSO: X24ESR-U
Gap 0.6-0. 7
(0.024-0.028)
Over 8 (0.3) at 1 atm.
Primary
3-5 terminal terminal
Secondary 17-28 terminal -
Plug cap
Ignition coil primary peak voltage
Generat or coil resistance
Pick-up coil peak voltage
Generat or Max. output
Generat or no-load voltage
Regulated voltage
Starter relay resistance
Battery Type designation
Capacity
Fuse size
Standard electrolyte S.G.
Main
Headlight
Headlight
HI
LO
Turn signal
Ignition
Taillight
Pick-up
Charging
More than 200 V
400-650
0.1-1. 5
More than 5.0 V
210Wat5 000r/min.
More than 60 V (AC) at 5 000 r/min.
13.5-15.0 Vat 5 000 r/min.
3-6
FTX7L-BS
12V21.6kC(6Ah)/10HR
1.320 at 20°C (68°F)
20A
15A
15A
15A
10A
10A
Bl-G
Y-Y
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7-31 SERVICING INFORMATION
WATTAGE
ITEM
Headlight HI
LO
Position light
Brake light/ Taillight
Turn signal light
Front turn signal light/Running light
Speedometer light
Neut ral indicator light
Turn signal indic ator light
High beam indicator light
E-01,02, 04,
17,22, 25,34
60
55
4
21/5
21
1.7
3.4
3.4
1.7
BRAKE + WHEEL
ITEM
Rear brake pedal free travel
Rear brake pedal height
Brake disc thickness
Brake disc runout
Master cylinder bore
Master cylinder piston diam.
Brake caliper cylinder bore
Brake caliper piston diam.
Brake drum I. D.
Brake lining thickness
Wheel rim runout
Wheel axle runout
Wheel rim size
Tire size
SPECIFICATION
E-24
Rear
Rear
Axial
Radial
Front
Rear
Front
Rear
Front
Rear
Front
Front
STANDARD
20-30
(0.8-1.2)
50
(2.0)
5.0 ± 0.2
(0.20 ±0.01)
12.700-12.743
(0.4999-0.5017)
12.657-12.684
(0.4983-0.4994)
33.960-34.036
(1.3370-1.3400)
33.884-33.934
(1.3340-1.3360)
16XMT2. 50
15XMT3. 00
110/90-16 59P
130/90-15M/ C66P
Unit: W
E-03, 28, 33
(rear)
21/5
Unit: mm (in)
LIMIT
4.5
(0.18)
0.30
(0.012)
130.7
(5.15)
1.5
(0.06)
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
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SERVICING INFORMATION 7-32
ITEM STANDARD
Tire tread depth Front
Rear
SUSPENSION
ITEM
Front fork stroke
STANDARD
120
(4.7)
LIMIT
Front fork spring free length 301
(11-9)
Front fork oil level
Rear wheel travel
105
(4.1)
90
(3.5)
Swingarm pivot shaft runout 0.3
(0.01)
TIRE PRESSURE
COLD INFLA TION
TIRE P RESSURE
NORMAL RIDING
SOLO RIDING kPa kg/cm
2 psi
DUA L RIDING kPa kg/cm
2 psi
FRONT
REAR
175
200
1.75
2.00
25
29
175
225
1.75
2.25
25
33
FUEL + OIL
ITEM
Fuel type
Fuel tank including reserve
Engine oil type and grade
Engine oil capacity
Front fork oil type
Front fork oil capacity (each leg)
Brake fluid type reserve
SPECIFICATION
Use only unleaded gasoline of at least 87 pump octane or 91 octane or higher rated by the research method. Gasoline cont aining MTBE
(Methyl Terti ary Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible.
Use only unleaded gasoline of at least 87 pump octane
method) or 91 octane or higher rated by the Research Met hod.
Gasoline used should be graded 91 octane or higher. An unleaded gasoline is recommended.
14 L (3.7/3.1
US/Imp gal)
2.9 L (0.8/0. 6
US/Imp gal)
SAE10W/40, APISForS G
Change 1 300 ml
(1.4/1.1 US/Imp qt)
Filter change
Overhaul
1 400 ml
(1.5/1.2 US/Imp qt)
1 700 ml
(1.8/1.5 US/Imp qt)
SUZU Klfork oilSS-08(#10)
369 ml
(12.5/ 13.0 US/ Imp oz)
DOT 4
LIMIT
1.6
(0.06)
2.0
(0.08)
Unit: mm (in)
NOTE
NOTE
E-03, 33
E-28
The others
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Prepared by
SUZUKI
MOTOR CORPORATION
Motorcycle Service Department
June, 1998
Part No. 99500-32100-01E
Printed in Japan
224
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