Suzuki RV125 Service Manual
The Suzuki RV125 is a compact motorcycle designed for efficient and reliable performance. This manual provides detailed instructions and procedures for inspection, servicing, and overhaul of its components, empowering you to maintain and repair your motorcycle effectively. With clear explanations and helpful diagrams, this guide ensures you have the knowledge to provide fast and reliable service to your customers.
Advertisement
Advertisement
9 9 5 0 0 - 3 1 2 3 3 - 0 1 E
FOREWORD
This manual contains an introductory description on the SUZUKI RV125 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.
!
Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider.
GROUP INDEX
GENERAL INFORMATION
PERIODIC MAINTENANCE
ENGINE
FUEL AND LUBRICATION
SYSTEM
CHASSIS
ELECTRICAL SYSTEM
SERVICING INFORMATION
RV125K4/K5 (’04, ’05-MODELS)
RV125K6 (’06-MODELS)
© COPYRIGHT SUZUKI MOTOR CORPORATION 2003
HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE LOOKING FOR:
1. The text of this manual is divided into sections.
2. The section titles are listed in the GROUP INDEX.
3. Holding the manual as shown at the right will allow you to find the first page of the section easily.
4. The contents are listed on the first page of each section to help you find the item and page you need.
COMPONENT PARTS AND WORK TO BE DONE
Under the name of each system or unit there is an exploded view which provides work instructions and other service information (e.g., tightening torque, lubricating points and locking agent points).
Example: Front wheel
1
Spacer
2
Bearing
3
Front axle spacer
4
Bearing
5
Brake disc
6
Speedometer gearbox
7
Balancer weight
A
Front axle
B
Brake disc bolt
C
Spoke nipple
ITEM
A
B
C
N · m kgf-m
65 6.5
23
4.5
2.3
0.45
SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table.
SYMBOL DEFINITION SYMBOL DEFINITION
Torque control required.
Data beside it indicates specified torque.
Apply THREAD LOCK “1322”.
99000-32110
Indicates service data.
Apply THREAD LOCK “1342”.
99000-32050
Apply THREAD LOCK SUPER “1360”.
99000-32130
Apply oil. Use engine oil unless otherwise specified.
Apply molybdenum oil solution.
(mixture of engine oil and SUZUKl
MOLY PASTE in a ratio of 1 : 1)
Apply SUZUKI SUPER GREASE “A”.
99000-25010
Apply SUZUKI SILICONE GREASE.
99000-25100
Apply SUZUKI MOLY PASTE.
99000-25140
G
Apply THERMO-GREASE.
99000-59029
Apply SUZUKI BOND “1207B”.
99000-31140
1216B
Apply SUZUKI BOND “1216B”.
99000-31230
Apply THREAD LOCK SUPER “1303”.
99000-32030
Apply or use brake fluid.
Measure in voltage range.
Measure in resistance range.
Measure in current range.
Measure in diode test range.
Measure in continuity test range.
Use special tool.
Use fork oil.
99000-99044-10G
GENERAL INFORMATION
GENERAL INFORMATION 1-1
1
CONTENTS
WARNING/CAUTION/NOTE .........................................................................1- 2
GENERAL PRECAUTIONS ...........................................................................1- 2
SUZUKI RV125K3 (’03-MODEL) ...................................................................1- 4
SERIAL NUMBER LOCATION ......................................................................1- 4
FUEL AND OIL RECOMMENDATION ..........................................................1- 4
FRONT FORK OIL .................................................................................1- 5
BREAK-lN PROCEDURES ...........................................................................1- 5
DIMENSIONS AND DRY MASS ............................................................1- 7
COUNTRY AND AREA CODES ....................................................................1- 9
1-2 GENERAL INFORMATION
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words.
!
Indicates a potential hazard that could result in death or injury.
"
Indicates a potential hazard that could result in 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 vehicle. In addition to the WARNINGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a particular service operation, ask a more experienced mechanic for advice.
GENERAL PRECAUTIONS
!
* Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the 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, radiator and exhaust system until they have cooled.
* After servicing the fuel, oil, exhaust or brake systems, check all of the lines, and fittings related to the system for leaks.
GENERAL INFORMATION 1-3
"
* If parts replacement is necessary, replace the parts with SUZUKI Genuine Parts or their equivalent.
* When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.
* Be sure to use special tools when instructed.
* Make sure that all parts used in reassembly are clean. Lubricate them when specified.
* Use the specified lubricants, bonds or sealant.
* When removing the battery, disconnect the negative cable first and then the positive cable.
When reconnecting the battery, connect the positive cable first and then the negative cable, and replace the terminal cover on the positive terminal.
* When performing service to electrical parts, if the service procedures not require use of battery power, disconnect the negative battery cable.
* When tightening the cylinder head, case bolts and nuts, tighten the larger sizes first. Always tighten the bolts and nuts from the inside working out, in a crisscross manner.
* Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking nuts, cotter pins, circlips and certain other parts as specified, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces.
* Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted.
* Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is smeared with them.
* After reassembling, check parts for tightness and proper operation.
* To protect the environment, do not unlawfully dispose of used motor oil and all other fluids: batteries and tires.
* To protect the Earth’s natural resources, properly dispose of used motorcycle and parts.
1-4 GENERAL INFORMATION
SUZUKI RV125K3 (’03-MODEL)
LEFT SIDE RIGHT SIDE
SERIAL NUMBER LOCATION
The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the right side of the steering head pipe. The engine serial number 2 is located on the left side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts.
FUEL AND OIL RECOMMENDATION
FUEL
Gasoline used should be graded 91 octane (Research Method) or higher. An unleaded gasoline type is recommended.
GENERAL INFORMATION 1-5
ENGINE OIL
Use a premium quality 4-stroke motor oil to ensure longer service life of your motorcycle. Use only oils which are rated SF or
SG under the API service classification.
The recommended viscosity is SAE 10W-40. If an SAE 10W-40 motor oil is not available, select an alternative according to the right chart.
BRAKE FLUID
#
Specification and classification: DOT 4
!
Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will result.
Do not use any brake fluid taken from old or used or unsealed containers.
Never re-use brake fluid left over from a previous servicing, which has been stored for a long period.
FRONT FORK OIL
SUZUKI FORK OIL #10 or an equivalent fork oil.
BREAK-lN PROCEDURES
During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. The general rules are as follows:
• Keep to these break-in throttle opening limits:
Initial 800 km: Less than 1/2 throttle
Up to 1 600 km: Less than 3/4 throttle
• Upon reaching an odometer reading of 1 600 km you can subject the motorcycle to throttle full operation.
• Do not maintain constant engine speed for an extended time period during any portion of the break-in. Try to vary the throttle position.
1-6 GENERAL INFORMATION
INFORMATION LABELS
NO.
LABEL or PLATE NAME
1 Fuel caution label
2 Tire information label
3 Warning safety label
4 Warning rear carrier label
5 ID plate
6 Anti-tamparing label
Head pipe (Right side)
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ...................................................... 2 140 mm
Overall width ....................................................... 860 mm
Overall height ...................................................... 1 120 mm
Wheelbase .......................................................... 1 385 mm
Ground clearance................................................ 215 mm
Seat height .......................................................... 770 mm
Dry mass ............................................................. 117 kg
ENGINE
Type .................................................................... Four-stroke, air-cooled, OHC
Number of cylinders ............................................ 1
Bore..................................................................... 57.0 mm
Stroke .................................................................. 48.8 mm
Displacement ...................................................... 125 cm³
Compression ratio ............................................... 9.2 : 1
Carburetor ........................................................... MIKUNI BS26
Air cleaner ........................................................... Polyurethane foam element
Starter system ..................................................... Electric
Lubrication system .............................................. Wet sump
Idle speed............................................................ 1 500 ± 100 r/min
DRIVE TRAIN
Clutch .................................................................. Wet multi-plate type
Transmission ....................................................... 6-speed constant mesh
Gearshift pattern ............................................... 1-down, 5-up
Primary reduction ratio ........................................ 3.470 (59/17)
Gear ratios, Low ................................................. 3.000 (33/11)
2nd .................................................. 1.857 (26/14)
3rd ................................................... 1.368 (26/19)
4th ................................................... 1.095 (23/21)
5th ................................................... 0.923 (24/26)
Top .................................................. 0.833 (20/24)
Final reduction ratio............................................. 3.400 (51/15)
Drive chain .......................................................... DID 428, 134 links
GENERAL INFORMATION 1-7
1-8 GENERAL INFORMATION
CHASSIS
Front suspension ................................................. Telescopic, coil spring, oil damped
Rear suspension .................................................. Swingarm type, coil spring, oil damped
Front suspension stroke....................................... 110 mm
Rear wheel travel ................................................. 136 mm
Caster .................................................................. 26°
Trail ...................................................................... 91 mm
Steering angle...................................................... 45° (right & left)
Turning radius ...................................................... 2.1 m
Front brake........................................................... Disc brake
Rear brake ........................................................... Drum brake
Front tire size ....................................................... 130/80-18M/C 66P, tube type
Rear tire size ........................................................ 180/80-14 M/C 78P, tube type
ELECTRICAL
lgnition type.......................................................... Electronic ignition (Transistorized) lgnition timing ....................................................... 13° B.T.D.C. at 1 500 r/min
Spark plug............................................................ NGK: CR8E or DENSO: U24ESR-N
Battery.................................................................. 12 V 21.6 kC (6 Ah)/10 HR
Generator............................................................. Three-phase A.C. generator
Fuse .....................................................................20 A
Headlight.............................................................. 12 V 60/55 W
Brake light/Taillight............................................... 12V 21/5 W
Position light.........................................................12 V 4 W ............. E-19
12 V 5 W ............. E-02
Turn signal light.................................................... 12 V 21W
Speedometer light................................................ 12 V 1.7 W
Neutral indicator light ........................................... 12 V 3.4 W
High beam indicator light ..................................... 12 V 1.7 W
Turn signal indicator light ..................................... 12 V 3.4 W
CAPACITIES
Fuel tank, including reserve ................................. 7.5 L
Reserve ............................................... 1.8 L
Engine oil, oil change ........................................... 850 ml with filter change ................................ 950 ml overhaul.............................................. 1 200 ml
Front fork (each leg)............................................. 230 ml
These specifications are subject to change without notice.
COUNTRY AND AREA CODES
The following codes stand for the applicable countries and areas.
CODE
E-02
E-19
COUNTRY OR AREA
U. K.
EU
GENERAL INFORMATION 1-9
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE 2-1
CONTENTS
PERIODIC MAINTENANCE SCHEDULE .......................................................2- 2
PERIODIC MAINTENANCE CHART .....................................................2- 2
LUBRICATION POINTS .........................................................................2- 3
MAINTENANCE AND TUNE-UP PROCEDURES ..........................................2- 4
VALVE CLEARANCE ............................................................................2- 5
THROTTLE CABLE PLAY .....................................................................2- 8
ENGINE IDLE SPEED ............................................................................2- 8
ENGINE OIL AND OIL FILTER ..............................................................2-10
TIRE AND WHEEL .................................................................................2-18
EXHAUST PIPE BOLTS AND MUFFLER MOUNTING BOLTS ............2-19
REAR SUSPENSION .............................................................................2-19
CHASSIS BOLTS AND NUTS ...............................................................2-20
COMPRESSION PRESSURE CHECK ............................................................2-22
COMPRESSION TEST PROCEDURE ...................................................2-22
OIL PRESSURE TEST PROCEDURE ...................................................2-23
2
6
2-2 PERIODIC MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE
The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy.
NOTE:
More frequent servicing may be performed on motorcycles that are use under severe conditions.
PERIODIC MAINTENANCE CHART
Item
Interval km months
Air cleaner element
Exhaust pipe bolts and muffler mounting bolts
Valve clearance
Spark plug
Fuel line
Engine oil filter
Engine oil
Throttle cable
Idle speed
Clutch
Drive chain
Brakes
Brake hose
Brake fluid
Tires and wheels
Steering
Front forks
Rear suspension
Chassis nuts and bolts
1 000
5
—
T
4 000
20
I
T
I
I
I
R
R
I
I
—
I
I
—
—
—
I
—
—
T
I
I
I
Replace every 4 years.
—
R
I
I
I
I
Clean and lubricate every 1 000 km.
I
I
Replace every 4 years.
I
Replace every 2 years.
I
—
—
—
T
I
R
I
I
I
I
R
R
I
I
I
I
I
I
I
I
T
8 000
40
I
T
NOTE:
I=Inspect and clean, adjust, replace or lubricate as necessary; C=Clean; R=Replace; T=Tighten
PERIODIC MAINTENANCE 2-3
LUBRICATION POINTS
Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.
Major lubrication points are indicated below.
Clutch lever holder
Side-stand pivot and spring hook
Drive chain
Brake lever holder and throttle cable
Brake pedal pivot
NOTE:
* Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.
* Lubricate exposed parts which are subject to rust, with a rust preventative spray especially whenever the motorcycle has been operated under wet or rainy condition.
2-4 PERIODIC MAINTENANCE
MAINTENANCE AND TUNE-UP PROCEDURES
This section describes the servicing procedures for each item in the Periodic Maintenance chart.
AIR CLEANER
Inspect every 4 000 km (20 months).
If the air cleaner is clogged with dust, intake resistance will be increase, resulting in a decrease in engine output and an increase in fuel consumption. Clean the air cleaner element in the following manner:
• Remove the left frame cover. (
!
5-3)
• Remove the air cleaner cover 1 .
• Remove the air cleaner element
2
.
• Fill a container with a non-flammable cleaning solvent.
• Immerse the air cleaner element in the cleaning solvent and wash it.
• Squeeze the cleaning solvent out of the washed element by pressing it between the palms of both hands: do not twist or wring the element or it will develop tears.
• Immerse the element in motor oil and squeeze the oil out of the element leaving it slightly wet with oil.
"
Inspect the air cleaner element for tears. A torn element must be replaced.
A Non-flammable cleaning solvent
B Motor oil SAE 30 or SAE 10W-40
• Remove the drain plug 1 to allow any water to drain out.
• Reinstall the cleaned air cleaner element in the reverse order of removal.
"
Be sure to position the element snugly and correctly, so that no incoming air will by-pass it. Remember, the rapid wear of piston rings and the cylinder bore is often caused by a defective or poorly fitted element.
"
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!
VALVE CLEARANCE
Inspect initially at 1 000 km (5 months) and every
4 000 km (20 months) thereafter.
REMOVAL
• Remove the seat. (
!
5-3)
• Remove the fuel tank. (
!
4-2)
• Remove the spark plug. (
!
2-7)
• Remove the valve inspection caps 1 .
• Remove the valve timing inspection plug 2 and generator cover plug 3 .
PERIODIC MAINTENANCE 2-5
2-6 PERIODIC MAINTENANCE
INSPECTION
The valve clearance specification is same for both valves. Valve clearance adjustment must be checked and adjusted, 1) at the time of periodic inspection, 2) when the valve mechanism is serviced, and 3) when the camshaft is disturbed by removing it for servicing.
NOTE:
* The piston must be at (TDC) on the compression stroke in order to check the valve clearance or to adjust valve clearance.
* The clearance specification is for COLD state.
* To turn the crankshaft for clearance checking, rotate in the normal running direction. The spark plug should be removed.
• Turn crankshaft to bring the “TDC” line A on the rotor to the index mark B on the generator cover.
• Insert a thickness gauge between the valve stem end and the adjusting screw on the rocker arm.
If the clearance is out of specification, bring it into the specified range.
#
09900-20803: Thickness gauge
09917-13210: Valve clearance adjusting driver
$
Valve clearance (when cold):
IN.: 0.08 – 0.13 mm
EX.: 0.13 – 0.18 mm
Lock nut
Adjuster
SPARK PLUG
Inspect every 4 000 km (20 months).
Replace every 8 000 km (40 months).
NGK
DENSO
STD
CR8E
U24ESR-N
Cold type
CR7E
U22ESR-N
Hot type
CR9E
U27ESR-N
• Disconnect the spark plug cap and remove the spark plug.
#
09930-10121: Spark plug wrench set
"
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.
• 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: 0.7 – 0.8 mm
• Check the spark plug for burns. If any abnormalities are found, replace the spark plug.
"
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 kgf-m)
#
09930-10121: Spark plug wrench set
PERIODIC MAINTENANCE 2-7
0.7 – 0.8 mm
2-8 PERIODIC MAINTENANCE
THROTTLE CABLE PLAY
Inspect initially at 1 000 km (5 months) and every
4 000 km (20 months) thereafter.
Throttle cable play A should be 2.0 – 4.0 mm as measured at throttle grip when turning the throttle grip lightly. If the play A is incorrect, adjust it as follows:
• Loosen the lock nut 1 and turn the adjuster 2 in or out until the specified play is obtained.
• Tighten the lock nut 1 while holding the adjuster 2 .
$
Throttle cable play A : 2.0 – 4.0 mm
&
After the adjustment is completed, check that handlebars movement does not raise the engine idle speed and that the throttle grip returns smoothly and automatically.
NOTE:
Major adjustment can be made by the carburetor side adjuster.
ENGINE IDLE SPEED
Inspect initially at 1 000 km (5 months) and every
4 000 km (20 months) thereafter.
• Adjust the throttle cable play. (See above.)
• Warm up the engine.
NOTE:
Make this adjustment when the engine is hot.
• Start the engine, turn the throttle stop screw 1 and set the engine idle speed as follows.
• Connect the electric tachometer or the multi circuit tester to the high-tension cord.
• Start the engine and set the engine idle speed between 1 400 and 1 600 r/min by turning the throttle stop screw 1 .
$
Engine idle speed: 1 500 ± 100 r/min
#
09900-26006: Tachometer, or
09900-25008: Multi circuit tester set
FUEL HOSE
Inspect initially at 1 000 km (5 months) and every
4 000 km (20 months) thereafter.
Replace every 4 years.
Inspect the fuel hose for damage and fuel leakage. If any damages are found, replace the fuel hose with a new one.
CLUTCH
Inspect initially at 1 000 km (5 months) and every
4 000 km (20 months) thereafter.
• Loosen the lock nut 1 and turn the adjuster 2 fully in.
• Loosen the lock nut 3 and turn the adjuster 4 until the clutch lever play A is within specification.
$
Clutch lever play A : 10 – 15 mm
• Tighten the lock nuts 1 , 3 .
PERIODIC MAINTENANCE 2-9
2-10 PERIODIC MAINTENANCE
ENGINE OIL AND OIL FILTER
ENGINE OIL REPLACEMENT
Replace initially at 1 000 km (5 months) and every
4 000 km (20 months) thereafter.
• Place an oil pan below the engine. Drain oil by removing the engine oil drain plug 1 .
• Remove the oil filler cap 2 .
• Tighten the engine oil drain plug
1
to the specified torque.
Pour new oil through the oil filler hole. When performing an oil change (without oil filter replacement), the engine will hold about 0.85 L of oil. Use an engine oil that meets API service classifications SF or SG and that has a viscosity rating of SAE
10W-40.
%
Engine oil drain plug 1 : 28 N·m (2.8 kgf-m)
• Make sure that the engine is cooled.
• Place the motorcycle on level ground and hold it vertically.
• Install the oil filler cap 2 .
• Start the engine and allow it to run for a few minutes at idling speed.
• Turn off the engine and wait about three minutes, and then check the oil level through the inspection window. If the oil level is below “L”, add oil to “F”. If the level is above “F”, drain oil to “F”.
OIL FILTER REPLACEMENT
Replace initially at 1 000 km (5 months) and every
8 000 km (40 months) thereafter.
• Drain engine oil as described in the engine oil replacement procedure.
• Remove the oil filter cap 1 and oil filter 2 .
• Replace the oil filter with a new one.
• Install the spring 3 correctly.
• Apply engine oil lightly to the O-rings 4 and 5 .
• Install the oil filter cap and tighten the nuts securely.
• Add new engine oil and check the oil level as described in the engine oil replacement procedure.
$
Engine oil capacity
Oil change: 0.85 L
Oil and filter change: 0.95 L
Engine overhaul: 1.2 L
"
Make sure that the oil filter is installed properly. If the filter is installed improperly, serious engine damage may result.
DRIVE CHAIN
Inspect initially at 1 000 km (5 months) and every
4 000 km (20 months) thereafter.
Clean and lubricate every 1 000 km.
Visually inspect the drive chain for the possible defects listed below.
* Loose pins
* Damaged rollers
* Twisted or seized links
* Excessive wear
* Rusted links * Kinked or binding links
If any defects are found, the drive chain must be replaced.
"
The standard drive chain is DID 428 SUZUKI recommends to use this standard drive chain as a replacement.
PERIODIC MAINTENANCE 2-11
2-12 PERIODIC MAINTENANCE
CHECKING AND ADJUSTING
• Loosen the rear axle nut 1 .
• Tense the drive chain fully by turning both chain adjusters
2
.
• 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: 259.0 mm
NOTE:
When replacing the drive chain, replace the drive chain and sprockets as a set.
• Place the motorcycle on the side-stand.
• Loosen or tighten both chain adjusters 1 until the chain has
15 – 25 mm of slack at the middle of the chain between the engine and rear sprockets as shown. The reference marks
2 must be at the same position on the scale to ensure that the front and rear wheels are correctly aligned.
$
Drive chain slack: 15 – 25 mm
• After adjusting the drive chain, tighten the rear axle nut
3
to the specified torque.
%
Rear axle nut: 65 N·m (6.5 kgf-m)
• Recheck the chain slack after tightening the axle nut and readjust if necessary.
• Tighten both chain adjusters
1
securely.
15 – 25 mm
PERIODIC MAINTENANCE 2-13
CLEANING AND LUBRICATING
• Clean the drive chain with kerosine. If the drive chain tends to rust quickly, the intervals must be shortened.
• After cleaning and drying the chain, oil it with a heavy-weight engine oil.
"
The drive chain joint clip should be attached in the way that the slit end will face opposite to the direction of travel.
BRAKES
(BRAKE)
Inspect initially at 1 000 km (5 months) and every
4 000 km (20 months) thereafter.
(BRAKE HOSE/BRAKE FLUID)
Inspect every 4 000 km (20 months).
Replace brake hose every 4 years.
Replace brake fluid every 2 years.
FRONT BRAKE PADS
The extent of brake pad wear can be checked by observing the grooved limit line A on the brake pad. When the wear exceeds the grooved limit line, replace the pads with new ones.
(
!
5-11)
"
Replace the brake pads as a set, otherwise braking performance will be adversely affected.
Direction of travel
2-14 PERIODIC MAINTENANCE
BRAKE HOSES
Check the brake hose for leakage, cracks, wear and damage. If any damages are found, replace the brake hoses with new a one.
BRAKE FLUID LEVEL
Inspect every 4 000 km (20 months).
Replace every 2 years.
• 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
&
* The brake system is filled with a glycol-based brake fluid, which is classified DOT 4. Do not use or mix other types of brake fluid, such as silicone-based and petroleum-based brake fluids when refilling the brake system, otherwise serious damage to the brake system will result.
* Do not use any brake fluid taken from old, used or unsealed containers.
* Do not reuse brake fluid left over from the last servicing or which has been stored for a long period of time.
* When storing brake fluid, make sure to seal the container completely and keep it out of the reach of children.
* When replenishing brake fluid, make sure not to get any dust or other foreign materials in the fluid.
* Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces. Check the brake hoses and hose joints for cracks and oil leakage before riding.
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 the top of the inspection window. Replace the reservoir cap to prevent dirt from entering.
• Attach a hose to the air bleeder valve 1 , 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 air 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 kgf-m)
"
Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials, etc.
PERIODIC MAINTENANCE 2-15
2-16 PERIODIC MAINTENANCE
REAR BRAKE PEDAL HEIGHT
• Loosen the lock nut 1 and rotate the adjusting bolt 2 to locate brake pedal 5 – 15 mm
A
below the top face of the footrest.
• Retighten the lock nut 1 to secure the adjusting bolt 2 in the proper position.
$
Brake pedal height
A
: 5 – 15 mm
REAR BRAKE ADJUSTING
• By repositioning the adjusting nut 3 on the brake rod, set the pedal play to between 20 – 30 mm B as measured at pedal tip.
$
Brake pedal free travel B : 20 – 30 mm
REAR BRAKE SHOE WEAR
This motorcycle is equipped with the brake lining wear limit indicator on the rear brake.
To check wear of the brake lining, perform the following steps:
• First, check if the brake system is properly adjusted.
• While operating the brake, check to see that the tip of indicator 1 is within the range 2 on the brake panel.
• If the tip of indicator 1 is beyond the range 2 , the brake shoe assembly should be replaced with a new set of shoe.
(
!
5-38)
BRAKE LIGHT SWITCH
Adjust the rear brake light switch so that the brake light will come on just before pressure is fell when the brake pedal is depressed.
STEERING
Inspect initially at 1 000 km (5 months) and every
8 000 km (40 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. (
!
5-28)
PERIODIC MAINTENANCE 2-17
2-18 PERIODIC MAINTENANCE
TIRE AND WHEEL
TIRE TREAD CONDITION
Inspect every 4 000 km (20 months).
Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of the tire tread reaches the following specification.
$
Tire depth limit Front: 4.0 mm
Rear: 4.0 mm
#
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 will increase. Therefore, maintain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows.
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
"
SOLO RIDING kPa
125
125 kgf/cm
1.25
1.25
2
DUAL RIDING kPa
125
125 kgf/cm
1.25
1.25
The standard tire fitted on this motorcycle is a 130/
80-18M/C 66P for the front and a 180/80-14M/C 78P for the rear. The use of tires other than those specified may cause instability. It is highly recommended to use the specified tires.
2
WHEEL
Make sure that the wheel runout (axial and radial) does not exceed the service limit when checked as shown. An excessive amount of runout is usually due to worn or loose wheel bearings and can be corrected by replacing the bearings. If bearing replacement fails to reduce the runout, replace the wheel.
(Wheel inspection:
!
5-50)
$
Wheel runout
Service Limit (axial and radial): 2.0 mm
SPOKE NIPPLES
Make sure that the nipples are tight. If necessary, tighten them with a spoke nipple wrench.
%
Spoke nipple: 4.5 N·m (0.45 kgf-m)
#
09940-60113: Spoke nipple wrench
EXHAUST PIPE BOLTS AND MUFFLER
MOUNTING BOLTS
Tighten initially at 1 000 km (5 months) and every
4 000 km (20 months) thereafter.
Cylinder head nuts, when they are not tightened to the specified torque, may result in leakage of the compressed mixture and reduce output.
• Tighten the exhaust pipe bolts and muffler mounting bolts to the specified torque.
%
Exhaust pipe bolt 1 : 23 N·m (2.3 kgf-m)
Muffler connecting bolt 2 : 20 N·m (2.0 kgf-m)
Muffler mounting bolt
3 4
: 23 N·m (2.3 kgf-m)
FRONT FORK
Inspect every 8 000 km (40 months).
Inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes. If any damages are found, replace the front fork with a new one.
REAR SUSPENSION
Inspect every 8 000 km (40 months).
Inspect the rear shock absorber for oil leakage and damage. If any damages are found, replace the rear shock absorber with a new one.
PERIODIC MAINTENANCE 2-19
2-20 PERIODIC MAINTENANCE
CHASSIS BOLTS AND NUTS
Tighten initially at 1 000 km (5 months) and every
4 000 km (20 months) thereafter.
Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-21 for the locations of the following bolts and nuts on the motorcycle.)
Item
1 Handlebar clamp bolt
2 Steering stem head nut
3 Front fork upper clamp bolt
4 Front fork lower clamp bolt
5 Front fork cap bolt
6 Front axle
7 Front axle pinch bolt
8 Front brake caliper mounting bolt
9 Front brake hose union bolt
0 Front brake caliper air bleeder valve
A Front brake master cylinder mounting bolt
B Swingarm pivot nut
C Rear axle nut
D Rear shock absorber mounting bolt/nut
(Upper & Lower)
E Front footrest bolt
F Rear brake cam lever nut
G Rear sprocket mounting nut
H Spoke nipple
N·m
23
90
23
33
23
65
23
39
23
7.5
10
65
65
50
94
7
60
4.5
kgf-m
2.3
9.0
2.3
3.3
2.3
6.5
2.3
3.9
2.3
0.75
1.0
6.5
6.5
5.0
9.4
0.7
6.0
0.45
PERIODIC MAINTENANCE 2-21
2-22 PERIODIC MAINTENANCE
COMPRESSION PRESSURE CHECK
The compression pressure reading of a cylinder is a good indicator of its internal condition.
The decision to overhaul the cylinder is often based on the results of a compression test. Periodic maintenance records kept at your dealership should include compression readings for each maintenance service.
CONPRESSION PRESSURE SPECIFICATION
Standard
1 300 – 1 700 kPa
(13 – 17 kgf/cm 2 , 185 – 242 psi)
Limit
980 kPa
(9.8 kgf/cm 2 , 140 psi)
Low compression pressure can indicate any of the following conditions:
* Excessively worn cylinder walls
* Worn piston or piston rings
* Piston rings stuck in grooves
* Poor valve seating
* Ruptured or otherwise defective cylinder head gasket
NOTE:
When the compression pressure goes below specification, check the engine for conditions listed above.
COMPRESSION TEST PROCEDURE
NOTE:
* Before testing the engine for compression pressure, make sure that the cylinder head nuts are tightened to the specified torque values and the valves are properly adjusted.
* Warm up the engine before testing.
* Make sure that the battery is fully-charged.
Remove the related parts and test the compression pressure in the following manner:
• Remove the spark plug. (
!
2-7)
• Install the compression gauge and adaptor in the spark plug hole. Make sure that the connection is tight.
• Keep the throttle 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 set
09913-10750: Adaptor
PERIODIC MAINTENANCE 2-23
OIL PRESSURE CHECK
Check the oil pressure periodically. This will give a good indication of the condition of the moving parts.
$
Oil pressure:
Above 15 kPa (0.15 kgf/cm²)
Below 35 kPa (0.35 kgf/cm²) at 3 000 r/min, oil temp. at 60 °C (140 °F)
Low or high oil pressure can indicate any of the following conditions:
LOW OIL PRESSURE
* Clogged oil filter
* Oil leakage from the oil passage
* Damaged O-ring
* Defective oil pump
* Combination of the above items
HIGH OIL PRESSURE
* Engine oil viscosity is too high
* Clogged oil passage
* Combination of the above items
OIL PRESSURE TEST PROCEDURE
• Connect a tachometer to the high-tension cord.
• Remove the main oil gallery plug 1 .
• Install the oil pressure gauge and adaptor into the main oil gallery.
• Warm up the engine as follows:
Summer: 10 minutes at 2 000 r/min
Winter: 20 minutes at 2 000 r/min
• After warming up the engine, increase the engine speed to
3 000 r/min (observe the tachometer), and read the oil pressure gauge.
#
09915-74510: Oil pressure gauge
09915-70610: Adaptor
ENGINE
CONTENTS
ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ..............3- 2
ENGINE REMOVAL AND INSTALLATION ....................................................3- 3
ENGINE REMOVAL ...............................................................................3- 3
ENGINE INSTALLATION .......................................................................3- 8
ENGINE COMPONENTS INSPECTION AND SERVICE ................................3-21
CYLINDER HEAD COVER .....................................................................3-21
CYLINDER HEAD ..................................................................................3-23
CAM CHAIN TENSION ADJUSTER ......................................................3-34
CAM CHAIN GUIDE ...............................................................................3-34
PISTON AND PISTON PIN ....................................................................3-34
CRANKSHAFT AND CONROD .............................................................3-37
STARTER CLUTCH AND STARTER DRIVEN GEAR BEARING .........3-39
GENERATOR STATOR AND PICK-UP COIL .......................................3-40
PRIMARY DRIVEN GEAR .....................................................................3-43
CRANKCASE BEARINGS .....................................................................3-46
GENERATOR COVER BEARING ..........................................................3-48
CLUTCH RELEASE CAMSHAFT ..........................................................3-49
PAIR CONTROL VALVE ........................................................................3-65
ENGINE 3-1
3
6
3-2 ENGINE
ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE
The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to the pages listed in each section for removal and reinstallation instructions.
ENGINE LEFT SIDE
Generator cover
Generator stator
Generator rotor
Starter idle gear
Neutral switch
PARTS REMOVAL
3-14
3-14
3-17
3-14
3-18
INSTALLATION
3-58
3-40
3-53
3-58
3-52
ENGINE RIGHT SIDE
Clutch cover
Clutch
Oil pump
Gearshift shaft
Gearshift cam driven gear
Primary driven gear
Oil pump drive gear
Primary drive gear
Oil filter
PARTS
ENGINE CENTER
PARTS
Cylinder head cover
Cam chain tension adjuster
Cylinder head
Camshaft sprocket
Cylinder
Cam chain
Camshaft
Piston
Oil sump filter
Clutch release camshaft
Gearshift cam stopper
Starter motor
REMOVAL
3-14
3-14
3-16
3-16
3-16
3-15
3-17
3-16
3-45
REMOVAL
3-12
3-12
3-13
3-12
3-13
3-18
3-12
3-13
3-45
3-49
3-18
3-14
INSTALLATION
3-58
3-56
3-55
3-55
3-54
3-56
3-53
3-53
3-45
INSTALLATION
3-63
3-64
3-60
3-62
3-60
3-53
3-61
3-60
3-45
3-49
3-52
3-58
ENGINE REMOVAL AND INSTALLATION
ENGINE REMOVAL
• Remove the seat. (
!
5-3)
• Remove the fuel tank. (
!
4-2)
• Drain engine oil. (
!
2-10)
• Disconnect the battery lead wire 1 .
• Loosen the muffler connecting bolt.
• Remove the exhaust pipe 2 .
• Disconnect the plug cap 3 .
• Remove the PAIR pipe 4 .
ENGINE 3-3
3-4 ENGINE
• Disconnect the starter motor lead wire 1 .
• Disconnect the throttle cable from the carburetor.
• Disconnect the neutral switch lead wire coupler 2 , pick-up coil lead wire coupler 3 and generator lead wire coupler 4 .
• Disconnect the throttle position sensor lead wire coupler 5 .
• Disconnect the carburetor heater lead wires 6 .
• Remove the carburetor.
• Remove the clutch release arm 1 along with the clutch cable.
• Disconnect the crankcase breather hose 2 .
• Remove the gearshift lever 3 .
• Remove the engine sprocket cover 4 .
Collar
Sprocket cover
Collar
Bolt
Spacer
ENGINE 3-5
3-6 ENGINE
• Loosen the engine sprocket nut 1 .
NOTE:
When loosening the engine sprocket nut 1 , depress the brake pedal.
• Remove the drive chain joint clip 2 .
• Release the chain.
• Disconnect the engine ground wire 3 .
• Remove the engine mounting nuts, bolts and brackets.
• Remove the swingarm pivot nut 1 .
• 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.
ENGINE 3-7
3-8 ENGINE
ENGINE INSTALLATION
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.
Left Right
40 N.m
(4.0 kgf-m)
41 N.m
(4.1 kgf-m)
88 N.m
(8.8 kgf-m)
40 N.m
(4.0 kgf-m)
41 N.m
(4.1 kgf-m)
65 N.m
(6.5 kgf-m)
"
The drive chain joint clip should be attached in the way that the slit end will face opposite to the direction of travel.
• Tighten the engine sprocket nut 1 to the specified torque.
#
Engine sprocket nut: 90 N·m (9.0 kgf-m)
ENGINE 3-9
• Install the clutch release arm as shown in the illustration.
NOTE:
Align the release arm slit surface A with the notch mark B on the release camshaft.
• Position the carburetor clamps as shown in the illustration.
Left Right Left Right
• Install the gasket 1 to the cylinder side.
• Install the PAIR air pipe and tighten the nuts to the specified torque.
#
PAIR air pipe nut: 10 N·m (1.0 kgf-m)
Engine side Air cleaner side
• Install a new exhaust pipe/muffler connector 2 into the muffler lip.
NOTE:
Exhaust gas sealer should be applied to both of the inside and outside of the connector 2 .
EXHAUST GAS SEALER: PERMATEX 1372
• Install the gasket 3 .
3-10 ENGINE
• Tighten the exhaust pipe bolts to the specified torque.
#
Exhaust pipe bolt: 23 N·m (2.3 kgf-m)
• Tighten the muffler connecting bolt to the specified torque.
#
Muffler connecting bolt: 20 N·m (2.0 kgf-m)
• Install the gearshift lever to the gearshift shaft in the correct position.
$
Gearshift lever height A : 20 mm
(between footrest top and gearshift lever top)
• After remounting the engine, the following adjustments are necessary.
* Clutch lever play . . . . . . . . . . . . . . . . . . . . .
!
2-9
* Throttle cable play . . . . . . . . . . . . . . . . . . . .
!
2-8
* Engine idle speed . . . . . . . . . . . . . . . . . . . .
!
2-8
* Drive chain slack . . . . . . . . . . . . . . . . . . . . .
!
2-12
"
Check the wire routing. (
!
7-11)
• Pour 1 200 ml of 10W-40 (SAE), SF or SG (API) engine oil into the engine after overhauling it. Start the engine and allow it to run for three minutes at idle speed. Turn off the engine and wait three minutes, and then check the oil level. If the level is below the “L” line, add oil until the level reaches the
“F” line. (
!
2-10)
ENGINE DISASSEMBLY
The procedure for engine disassembly is sequentially explained in the following steps:
• Remove the spark plug 1 .
%
09930-10121: Spark plug wrench set
• Remove the engine sprocket 2 .
• Remove the timing inspection plug 3 and generator cover plug 4 .
• Rotate the crankshaft and align the line A on the generator rotor with the mark B on the generator cover.
NOTE:
The piston must be at TDC on the compression stroke.
ENGINE 3-11
3-12 ENGINE
CAM CHAIN TENSION ADJUSTER
• Remove the cam chain tension adjuster 1 .
CYLINDER HEAD COVER
• Remove the cylinder head cover.
CAMSHAFT
• Remove the camshaft end cap 2 .
• Flatten the lock washer and remove the camshaft sprocket bolts.
• Remove the camshaft 3 and camshaft sprocket 4 .
"
Do not drop the cam chain
5
into the crankcase.
• Remove the C-ring 6 .
"
Do not drop the C-ring 6 into the crankcase.
CYLINDER HEAD
• Remove the cylinder head nuts (M6).
• Remove the cylinder head nuts (M8) diagonally.
• Remove the cylinder head.
NOTE:
If the cylinder head does not come off, lightly tap on the finless portion of it with a plastic hammer.
CYLINDER
• Remove the gasket 1 .
• Remove the cam chain guide 2 .
• Remove the cylinder by removing the cylinder base nuts.
NOTE:
If the cylinder does not come off, lightly tap on the finless portion of it with a plastic hammer.
PISTON
• Place a clean rag over the cylinder base to prevent the piston pin circlip 3 from dropping into the crankcase. Then, remove the piston pin circlip 3 .
• Remove the piston pin.
NOTE:
Use the special tool if necessary.
%
09910-34510: Piston pin puller
• Remove the piston.
ENGINE 3-13
3-14 ENGINE
GENERATOR COVER
• Remove the generator cover 1 .
STARTER MOTOR
• Remove the spacer 2 , shaft 3 and starter idle gear 4 .
• Remove the starter motor 5 .
CLUTCH COVER
• Remove the clutch cover 6 .
CLUTCH
• With the generator rotor nut held immovable, remove the clutch spring mounting bolts in a crisscross pattern, and remove the clutch springs and clutch pressure plate 7 .
• Remove the washer 1 , bearing 2 , clutch push piece 3 and clutch push rod 4 .
• Remove the clutch drive and driven plates.
• Flatten the lock washer and remove the clutch sleeve hub nut
5 with the special tool.
%
09920-53740: Clutch sleeve hub holder
• Remove the clutch sleeve hub 6 .
• Remove the washer and primary driven gear assembly 7 .
• Remove the spacer 8 and washer .
ENGINE 3-15
3-16 ENGINE
OIL PUMP
• Remove the circlip 1 and oil pump driven gear 2 .
• Remove the pin 3 .
• Remove the oil pump 4 .
"
Do not attempt to disassemble the oil pump assembly.
GEARSHIFT
• Remove the gearshift shaft
5
.
• Remove the pawl lifter 6 and cam guide 7 .
• Remove the gearshift cam driven gear 8 .
NOTE:
When removing the cam driven gear 8 , do not lose the pawls
9 , pins 0 and springs A .
PRIMARY DRIVE GEAR
• Flatten the lock washer of the primary drive gear nut
B
.
• While holding the generator rotor with the special tool, remove the primary drive gear/oil pump drive gear nut.
%
09930-44530: Rotor holder
"
The primary drive gear/oil pump drive gear nut has left-hand threads.
• Remove the oil pump drive gear 1 and primary drive gear 2 .
• Remove the key 3 .
GENERATOR ROTOR
• Remove the generator rotor nut with the special tool.
%
09930-44530: Rotor holder
• Remove the generator rotor with the special tool.
%
09930-34932: Rotor remover
CAM CHAIN
• Remove the generator rotor key
4
and starter driven gear
5
.
ENGINE 3-17
3-18 ENGINE
• Remove the cam chain 1 .
NEUTRAL SWITCH
• Remove the plate 2 and neutral switch 3 .
• Remove the O-ring 4 , switch contact 5 and spring 6 .
• Remove the engine sprocket spacer 7 .
• Remove the oil seal retainer 8 .
• Remove the gearshift cam stopper.
• Remove the crankcase bolts.
• Separate the left and right crankcases with 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 gearshift fork shafts ( 1 , 2 ) and gearshift forks
( 3 , 4 ).
• Remove the gearshift cam stopper spring 5 .
• Remove the gearshift cam 6 .
• Remove the gearshift fork 7 .
• Remove the driveshaft assembly and countershaft assembly.
• Remove the gearshift cam stopper 8 .
ENGINE 3-19
3-20 ENGINE
CRANKSHAFT
• Remove the crankshaft with the special tool.
%
09920-13120: Crankcase separator
ENGINE COMPONENTS INSPECTION AND SERVICE
CYLINDER HEAD COVER
"
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 inspection caps 1 .
• Remove the rocker arm shaft bolts 2 .
• Remove the rocker arm shafts 3 .
• Remove the rocker arms 4 and wave washers 5 .
CYLINDER HEAD COVER DISTORTION
After removing sealant from the fitting surface of the cylinder head cover, place the cylinder head cover on a surface plate and check for distortion with a thickness gauge. Check points are shown in Fig.
$
Cylinder head cover distortion
Service Limit: 0.05 mm
%
09900-20803: Thickness gauge
If the distortion exceeds the limit, replace the cylinder head cover.
ROCKER ARM SHAFT O.D.
Measure the diameter of the rocker arm shafts.
$
Rocker arm shaft O.D.
Standard (IN. & EX.): 11.977 – 11.995 mm
%
09900-20205: Micrometer
ENGINE 3-21
3-22 ENGINE
ROCKER ARM I.D.
Measure the inside diameter of the rocker arm and check the wear of the camshaft contacting surface.
$
Rocker arm I.D.
Standard (IN. & EX.): 12.000 – 12.018 mm
%
09900-20605: Dial calipers
REASSEMBLY
Reassemble the cylinder head cover in the reverse order of disassembly. Pay attention to the following points:
• Apply engine oil to the rocker arm shafts.
• Install the rocker arms 1 , wave washers 2 and shafts 3 .
"
Use the new O-rings
A
to prevent oil leakage.
• Tighten the rocker arm shaft bolts to the specified torque.
#
Rocker arm shaft bolt: 9 N·m (0.9 kgf-m)
"
Install the gasket washer to the bolts
B
.
CYLINDER HEAD
"
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 1 .
• Remove the intake pipe 2 .
• Compress the valve spring with the special tools.
%
09916-14510: Valve lifter
09916-14910: Valve lifter attachment
• Remove the valve cotters 3 from the valve stem.
%
09916-84511: Tweezers
• Remove the valve spring retainer 4 and inner and outer valve springs ( 5 , 6 ).
ENGINE 3-23
3-24 ENGINE
• Remove the valve from the combustion chamber side.
• Remove the valve stem seal 1 .
• Remove the valve spring seat 2 .
CYLINDER HEAD DISTORTION
Decarbonize the combustion chamber.
Check the gasket surface of the cylinder head for distortion using a straightedge and thickness gauge. Take clearance readings at several places. If readings exceed the service limit, replace the cylinder head.
$
Cylinder head distortion
Service Limit: 0.05 mm
%
09900-20803: Thickness gauge
VALVE FACE WEAR
The thickness of the valve face decreases as the face wears.
Visually inspect each valve face for wear and replace any valve with an abnormally worn face. Measure the valve face thickness
T , if it is out of specification, replace the valve with a new one.
$
Valve head thickness
Service Limit: 0.5 mm
%
09900-20101: Venier calipers
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.
$
Valve stem runout
Service Limit: 0.05 mm
%
09900-20606: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
09900-21304: V-block (100 mm)
VALVE HEAD RADIAL RUNOUT
Place the dial gauge at a right angle to the valve head face and measure the valve head radial runout.
If it measures more than the service limit, replace the valve.
$
Valve head radial runout
Service Limit: 0.03 mm
%
09900-20606: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
09900-21304: V-block (100 mm)
VALVE STEM DEFLECTION
Lift the valve about 10 mm (0.4 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.
$
Valve stem deflection
Service Limit (IN. & EX.): 0.35 mm
%
09900-20606: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
VALVE STEM WEAR
Measure the valve stem O.D. using the micrometer. If it is out of specification, replace 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. After replacing the valve or valve guide, re-check the deflection.
$
Valve stem O.D.
Standard:
IN.: 5.475 – 5.490 mm
EX.: 5.455 – 5.470 mm
%
09900-20205: Micrometer (0 – 25 mm)
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.
ENGINE 3-25
3-26 ENGINE
• 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.
• 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
"
Be sure to use a new valve guide ring and valve guide.
NOTE:
Install the valve guide until the ring
A
contacts with the cylinder head.
• 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 INSPECTION
Visually check for valve seat width on each valve face.
If the valve face has worn abnormally, replace the valve.
Coat the valve seat with Prussian Blue and set the valve in place. Rotate the valve with light pressure. Check that the transferred blue on the valve face is uniform all around and in center of the valve face.
If the seat width W measured exceeds the standard value, or seat width is not uniform, reface the seat using the seat cutter.
$
Valve seat width W
Standard: 0.9 – 1.1 mm
%
09916-10911: Valve lapper set
If the valve seat is out of specification, correct the seat by servicing it as follows:
VALVE SEAT SERVICE
The valve seats for both intake and exhaust valves are machined to two different angles. (The seat contact surface is cut at 45°.)
15°
45°
INTAKE SIDE
N-212
N-122
15°
45°
EXHAUST SIDE
N-121
N-122
%
09916-20620: Valve seat cutter (N-122)
09916-21111: Valve seat cutter set
09916-24480: Solid pivot (N-140-5.5)
09916-24920: Valve seat cutter (N-212)
NOTE:
Use the solid pilot (N-140-5.5) along with the valve seat cutter
(N-121, -122 and -212)
"
The valve seat contact area must be inspected after each cut.
• When installing the solid pilot
1
, rotate it slightly.
ENGINE 3-27
45˚ 15˚
Valve seat
45˚
15˚
45˚
15˚
• Seat the pilot snugly. Install the 45° cutter
2
, attachment
3 and T-handle 4 .
3-28 ENGINE
INITIAL SEAT CUT
• Using the 45° cutter, descale and clean up the seat. Rotate the cutter one or two turns.
• Measure the valve seat width W after every cut.
45˚
• If the valve seat is pitted or burned, use the 45° cutter to condition the seat some more.
NOTE:
Cut only the minimum amount necessary from the seat to prevent the possibility of the valve stem becoming too close to the rocker arm for correct valve contact angle.
TOP NARROWING CUT
• 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.
Contact area too high and too wide on face of valve
(Use the 15° cutter.)
15˚
FINAL SEAT CUT
• If the contact area is too low or too narrow, use the 45° cutter to raise and widen the contact area.
NOTE:
After cutting the 15° angle, it is possible that the valve seat (45°) is too narrow. If so, re-cut the valve seat to the correct width.
• After the desired seat position and width is achieved, use the
45°cutter very lightly to clean up any burrs caused by the previous cutting operations.
Contact area too low and too narrow on face of valve
"
Do not use lapping compound after the final cut is made. The finished valve seat should have a velvety smooth finish but not a highly polished or shiny finish. This will provide a soft surface for the final seating of the valve which will occur during the first few seconds of engine operation.
NOTE:
After servicing the valve seats, be sure to check the valve clearance after the cylinder head has been reinstalled. (
!
2-5)
VALVE SEAT SEALING CONDITION INSPECTION
With the valve and valve spring assembled, pour a small quantity of gasoline into the intake or exhaust port.
Check that no gasoline leaks through the valve seat. If leakage is found, correct the sealing surface.
&
Always use extreme caution when handling gasoline.
VALVE STEM END CONDITION
Inspect the valve stem end face for pitting and wear. If pitting or wear is present, resurface the valve stem end. Make sure that the length
A
is not less than 2.5 mm. If this length becomes less than 2.5 mm, replace the valve.
$
Valve stem end length
Service Limit: 2.5 mm
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.
$
Valve spring free length (IN. & EX.)
Service Limit INNER : 36.8 mm
OUTER: 40.1 mm
%
09900-20101: Venier calipers
45˚
ENGINE 3-29
3-30 ENGINE
!
Valve spring tension (IN. & EX.)
Standard INNER : 76 – 90 N/32.5 mm
(7.8 – 9.2 kgf/32.5 mm)
OUTER: 186 – 219 N/36.0 mm
(18.9 – 22.3 kgf/36.0 mm)
CAM CHAIN TENSIONER
Inspect the cam chain tensioner for damage. If any damage are found, replace the cam chain tensioner with a new one.
REASSEMBLY
Reassemble the cylinder head in the reverse order of disassembly. Pay attention to the following points:
• Install each valve spring seat 1 .
• Apply molybdenum oil solution to the valve stem seal 2 , and press-fit the seal into position by hand.
"
Do not reuse the valve stem seals.
#
MOLYBDENUM OIL SOLUTION
• Apply molybdenum oil solution to the valve stems.
"
When inserting each valve, take care not to damage the lip of the stem seal.
#
MOLYBDENUM OIL SOLUTION
• Install the valve springs with the smaller pitch A facing the cylinder head.
• Install the valve spring retainer 1 , 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 cotters 2 to wedge between the retainer and the valve stem. Be sure that the rounded lip 3 of the cotter fits snugly into the groove 4 in the stem end.
%
09916-14510: Valve lifter
09916-14910: Valve lifter attachment
09916-84511: Tweezers
"
Be sure to install all of the parts in their original positions.
INTAKE PIPE
• When installing the intake pipe, apply grease to the O-ring.
(
99000-25010: SUZUKI SUPER GREASE “A”
"
Use the new O-ring to prevent sucking air from the joint.
NOTE:
Make sure that the protrusion A comes to the right side.
ENGINE 3-31
Towards
Cylinder head
3-32 ENGINE
CAM CHAIN TENSIONER
• Install the cam chain tensioner 1 .
• Tighten the cam chain tensioner bolt
2
to the specified torque.
#
Cam chain tensioner bolt: 13 N·m (1.3 kgf-m)
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 H using the micrometer. Replace a camshaft if the cams are worn to the service limit.
$
Cam height H
Service Limit IN.: 33.87 mm
EX.: 33.50 mm
%
09900-20202: Micrometer (25 – 50 mm)
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 1 .
%
09900-22301: Plastigauge
09900-22302: Plastigauge
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 kgf-m)
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.
$
Camshaft journal oil clearance
Service Limit: 0.150 mm
If the camshaft journal oil clearance exceeds the limit, measure the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal. Replace the camshaft or the cylinder head depending upon which one exceeds the specification.
$
Camshaft journal holder I.D.
Standard: 22.012 – 22.025 mm
%
09900-22403: Small bore gauge
$
Camshaft journal O.D.
Standard: 21.959 – 21.980 mm
%
09900-20205: Micrometer (0 – 25 mm)
CAMSHAFT RUNOUT
Measure the runout using a dial gauge. Replace the camshaft if the runout exceeds the limit.
$
Camshaft runout
Service Limit: 0.10 mm
%
09900-20606: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
09900-21304: V-block (100 mm)
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.
$
Cylinder distortion
Service Limit: 0.05 mm
%
09900-20803: Thickness gauge
ENGINE 3-33
3-34 ENGINE
CYLINDER BORE
Measure the cylinder bore diameter at six places.
If any one of the measurements exceed the limit, overhaul the cylinder and replace the piston with an oversize piston, or replace the cylinder.
!
Cylinder bore
Service Limit: 57.090 mm
"
09900-20508: Cylinder gauge set
CAM CHAIN TENSION ADJUSTER
Make sure the push rod movement. If the push rod is stuck or spring mechanism failed, replace the cam chain tension adjuster assembly with a new one.
CAM CHAIN GUIDE
Inspect the cam chain guide for damage. If any damage are found, replace the cam chain guide with a new one.
PISTON AND PISTON PIN
DIAMETER
Measure the piston diameter using the micrometer at 8 mm from the skirt end.
If the piston diameter is less than the service limit, replace the piston.
!
Piston diameter
Service Limit: 56.880 mm
Piston oversize: 0.5 mm
"
09900-20203: Micrometer (50 – 75 mm)
8 mm
PISTON-TO-CYLINDER CLEARANCE
Subtract the piston diameter from the cylinder bore diameter. If the piston-to-cylinder clearance exceeds the service limit, rebore the cylinder and use an oversize piston or replace both the cylinder and the piston.
$
Piston-to-cylinder clearance
Service Limit: 0.120 mm
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.
$
Piston ring to groove clearance
Service Limit 1st : 0.18 mm
2nd : 0.15 mm
%
09900-20803: Thickness gauge
09900-20205: Micrometer (0 – 25 mm)
$
Piston ring groove width
Standard 1st and 2nd: 1.01 – 1.03 mm
Oil : 2.01 – 2.03 mm
$
Piston ring thickness
Standard 1st and 2nd: 0.970 – 0.990 mm
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 calipers.
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.
$
Piston ring free end gap
Service Limit 1st : 5.8 mm
2nd : 4.0 mm
%
09900-20101: Venier calipers
$
Piston ring end gap
Service Limit 1st and 2nd: 0.7 mm
%
09900-20803: Thickness gauge
ENGINE 3-35
3-36 ENGINE
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
Oversize oil ring
The following oversize oil ring is used. It bears the following identification mark.
Oil ring 0.5 mm: Painted red
Oversize side rail
Measure the outside diameter to identify the size.
PISTON 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.
$
Piston pin bore
Service Limit: 14.030 mm
$
Piston pin O.D.
Service Limit: 13.980 mm
%
09900-20605: Dial calipers
09900-20205: Micrometer
Paint
0.5 mm O.S.
Oil ring spacer
CRANKSHAFT AND CONROD
ENGINE 3-37
1
Crankshaft, RH
2
Conrod
3
Bearing
4
Crank pin
5
Crankshaft, LH
@
ITEM
A
N·m
50 kgf-m
5.0
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.
$
Conrod small end I.D.
Service Limit: 14.040 mm
%
09900-20605: Dial calipers
3-38 ENGINE
CONROD DEFLECTION AND CONROD BIG END SIDE
CLEARANCE
Wear on the big end of the conrod can be estimated by checking the movement of the small end of the rod. This method can also check the extent of wear on the parts of the conrod’s big end.
$
Conrod deflection
Service Limit: 3.0 mm
%
09900-20701: Magnetic stand
09900-20606: Dial gauge (1/100 mm)
09900-21304: V-block set (100 mm)
Push the big end of the conrod to one side and measure the side clearance using a thickness gauge.
$
Conrod big end side clearance
Service Limit: 1.0 mm
%
09900-20803: Thickness gauge
If the clearance exceeds the service limit, replace crankshaft assembly or bring the deflection and side clearance into specification by replacing the worn parts. (e.g., conrod, big end bearing and crank pin)
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. If the runout exceeds the service limit, correct the runout or replace the crankshaft assembly.
$
Crankshaft runout
Service Limit: 0.08 mm
%
09900-20701: Magnetic stand
09900-20606: Dial gauge (1/100 mm)
09900-21304: V-block set (100 mm)
REASSEMBLY
• When rebuilding the crankshaft, the width between the webs
A should be within the standard range.
$
Crank web to web width A : 53.0 ± 0.1 mm
STARTER CLUTCH AND STARTER DRIVEN GEAR BEARING
ENGINE 3-39
Starter driven gear
Roller
Push piece
Spring
Generator motor
10 N.m
(1.0 kgf-m)
STARTER CLUTCH
Install the starter driven gear onto the starter clutch and turn the starter driven gear by hand (the gear turns in only one direction).
The starter driven gear should turn smoothly. If excessive resistance is felt while turning the starter driven gear, inspect the starter clutch. Also, inspect the surface of the starter driven gear which contacts the starter clutch, for wear or damage. If any wear or damage is found, replace the defective part(-s).
STARTER DRIVEN GEAR BEARING
Install the starter driven gear bearing 1 and gear 2 onto the crankshaft and turn the starter driven gear by hand. Inspect the starter driven gear bearing for smooth rotation and any abnormal noise. If the bearing does not turn smoothly or there is any abnormal noise, replace it.
DISASSEMBLY
• Remove the starter driven gear.
• Remove the roller 3 , spring 4 and push piece 5 .
3-40 ENGINE
• Hold the generator rotor with the rotor holder and remove the starter clutch bolts.
%
09930-44530: Rotor holder
REASSEMBLY
• Apply a small quantity of THREAD LOCK SUPER to the starter clutch bolts and tighten them to the specified torque while holding the rotor holder.
)
99000-32030: THREAD LOCK SUPER “1303”
%
09930-44530: Rotor holder
#
Starter clutch bolt: 10 N·m (1.0 kgf-m)
GENERATOR STATOR AND PICK-UP COIL
• When replacing the generator stator 1 or pick-up coil 2 , apply THREAD LOCK to the generator stator set bolts and pick-up coil set bolts and tighten them.
*
99000-32050: THREAD LOCK “1342”
TRANSMISSION
DISASSEMBLY
• Disassemble the transmission gears as shown in the illustration.
NOTE:
When removing the 2nd drive gear, use a gear puller and a proper attachment.
ENGINE 3-41
1
1st driven gear
2
5th driven gear
3
4th driven gear
4
3rd driven gear
5
Top driven gear
6
2nd driven gear
7
Driveshaft
8
Countershaft/1st drive gear
9
5th drive gear
0
4th drive gear
A
3rd drive gear
B
Top drive gear
C
2nd drive gear
REASSEMBLY
Assemble the countershaft and driveshaft in the reverse order of disassembly. Pay attention to the following points:
NOTE:
Before installing the gears, apply engine oil to the bearing and inner surface of the each gear.
"
* Never reuse a snap ring. After a snap ring has been removed from a shaft, it should be discarded and a new snap ring must be installed.
* When installing a new snap ring, do not expand the end gap larger than required to slip the snap ring over the shaft.
* After installing a snap ring, make sure that it is completely seated in its groove and securely fitted.
3-42 ENGINE
• When installing a new snap ring, pay attention to the direction of the snap ring. Fit the snap ring to the side where the thrust is as shown in the illustration. The rounded side should be against the gear surface.
• Press fitted 2nd drive gear onto the countershaft. Before reassembling, coat the internal face of the 2nd drive gear with
THREAD LOCK SUPER and install the gears so that the length A is as shown.
$
Countershaft length A : 88.0
+0.1
0 mm
)
99000-32030: THREAD LOCK SUPER “1303”
NOTE:
This procedure may be performed only twice before shaft replacement is required.
Thrust
Sharp edge
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 gearshift forks plays an important role in the smoothness and positiveness of the shifting action. Each fork has its prongs fitted into the annular 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 the gear axially.
If the clearance is too great, the meshed gears may slip apart.
If the clearance exceeds the specification, replace the fork, its respective gear or both.
$
Gearshift fork to groove clearance
Service Limit: 0.5 mm
%
09900-20803: Thickness gauge
$
Gearshift fork groove width
Standard
No. 1: 5.0 – 5.1 mm
No. 2: 5.5 – 5.6 mm
%
09900-20101: Venier calipers
$
Shift fork thickness
Standard
No. 1: 4.8 – 4.9 mm
No. 2: 5.3 – 5.4 mm
PRIMARY DRIVEN 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.
1 Primary driven gear
2 Damper
3 Clutch housing
ENGINE 3-43
3-44 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.
$
Clutch drive plate thickness
Service Limit: 2.65 mm
%
09900-20101: Venier calipers
$
Clutch drive plate claw width
Service Limit: 11.5 mm
CLUTCH DRIVEN PLATES
Measure each clutch driven plates for distortion using the thickness gauge. If a clutch driven plate is not within the service limit, replace the clutch plates as a set.
$
Clutch driven plate distortion
Service Limit: 0.10 mm
%
09900-20803: Thickness gauge
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.
$
Clutch spring free length
Service Limit: 31.0 mm
%
09900-20101: Venier calipers
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.
OIL FILTER
REMOVAL AND INSTALLATION
• Remove the oil filter cap 1 .
• Remove the oil filter 2 and install a new one.
NOTE:
Before installing the new oil filter and oil filter cap, make sure that the spring 3 and new O-rings ( 4 , 5 ) are installed correctly.
• Apply engine oil to the O-rings 4 and 5 .
• Install the oil filter cap.
OIL SUMP FILTER
REMOVAL
• Remove the oil sump filter cap 1 .
• Remove the oil sump filter 2 .
CLEANING AND INSPECTION
Clean the oil sump filter with a compressed air.
Check the oil sump filter for any damage or clogs.
INSTALLATION
• Install the oil sump filter in the reverse order of removal.
"
Replace the O-ring
3
with a new one.
ENGINE 3-45
3-46 ENGINE
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 1 and 2 .
Play
Play
• Remove the oil seals 3 and 4 with the special tool.
%
09913-50121: Oil seal remover
"
The removed oil seals should be replaced with new ones.
• Remove the washer
5
.
• Remove the bearings.
%
09921-20240: Bearing remover set (for 6789A )
09921-20210: Bearing remover (for 0 )
09930-30102: Sliding shaft
"
The removed bearings should be replaced with new ones.
CRANKSHAFT BEARING INSTALLATION
• Install the crankshaft bearings with the special tool.
%
09913-70210: Bearing installer set
DRIVESHAFT BEARING INSTALLATION
• Install the driveshaft bearings using the special tool.
%
09913-70210: Bearing installer set
• Install the washer 1 .
• Apply a small quantity of SUZUKI SUPER GREASE to the lip of the oil seal.
(
99000-25010: SUZUKI SUPER GREASE “A”
• Install the oil seal using the special tool.
%
09913-70210: Bearing installer set
• Install the bearing retainer 2 .
NOTE:
Apply a small quantity of THREAD LOCK to the bearing retainer screws.
*
99000-32050: THREAD LOCK “1342”
COUNTERSHAFT BEARING INSTALLATION
• Install the countershaft bearings with the special tools.
%
09913-70210: Bearing installer set
• Install the bearing retainer 3 .
NOTE:
Apply a small quantity of THREAD LOCK to the bearing retainer screws.
*
99000-32050: THREAD LOCK “1342”
ENGINE 3-47
3-48 ENGINE
GENERATOR COVER BEARING
REMOVAL
• Remove the dust seal 1 .
%
09913-50121: Oil seal remover
"
The removed oil seals should be replaced with new ones.
• Remove the generator cover bearing 2 .
%
09921-20240: Bearing remover set
"
The removed bearing should be replaced with new ones.
• Remove the dust seal
3
.
%
09913-70210: Bearing installer set
INSTLLATION
• Install the dust seals and bearing with the special tool.
%
09913-70210: Bearing installer set
• Apply a small quantity of SUZUKI SUPER GREASE to the lip of the dust seal.
(
99000-25010: SUZUKI SUPER GREASE “A”
CLUTCH RELEASE CAMSHAFT
REMOVAL
• Remove the oil seal retainer 1 .
• Remove the clutch release camshaft 2 .
REASSEMBLY AND INSTALLATION
• Apply a small quantity of SUZUKI SUPER GREASE to the lip of the oil seal.
(
99000-25010: SUZUKI SUPER GREASE “A”
• Install the clutch release camshaft 2 , washer 3 and new oil seal 4 .
• Install the oil seal retainer 1 .
ENGINE 3-49
3-50 ENGINE
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
09910-20116: Conrod holder
"
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.
TRANSMISSION
• Install the countershaft and driveshaft assemblies.
GEARSHIFT CAM AND GEARSHIFT FORKS
• Align the pin groove A of gearshift cam stopper plate with the pin
B
on the gearshift cam.
• Install the gearshift cam stopper and spring.
• Install the gearshift forks and gearshift cam.
1 : Gearshift fork No. 1
2 : Gearshift fork No. 2
3 : Gearshift fork No. 3
• Install the gearshift fork shafts ( 4 , 5 ).
NOTE:
Two kinds of gearshift forks ( A , B ) are used. They resemble each other very closely in external appearance and configuration. Carefully examine the illustration for correct installing positions and directions.
CRANKCASE
• Wipe both crankcase mating surfaces with a cleaning solvent.
• Apply SUZUKI BOND uniformly to the mating surface of the right crankcase and assemble the cases within a few minutes.
+
99104-31140: SUZUKI BOND “1207B”
ENGINE 3-51
• Install the dowel pins into the left half of the crankcase.
• 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 kgf-m)
• Install the clamp to the bolt A .
3-52 ENGINE
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 gearshift cam stopper.
ENGINE SPROCKET SPACER
• Apply SUZUKI SUPER GREASE to the oil seal lip.
(
99000-25010: SUZUKI SUPER GREASE “A”
• Install the oil seal retainer 1 .
• Install the clamp to the bolt A .
• Apply SUZUKI SUPER GREASE to the O-ring of the engine sprocket spacer. When installing the engine sprocket spacer onto the driveshaft, face its grooves B toward inside.
(
99000-25010: SUZUKI SUPER GREASE “A”
"
Use a new O-ring.
NEUTRAL SWITCH
• Install the spring
2
, neutral switch contact
3
and O-ring
4
.
• Install the neutral switch 5 and plate 6 .
"
Use a new O-ring.
GENERATOR ROTOR
• Install the cam chain.
• Remove any grease from the tapered portion of the generator rotor and crankshaft.
• Install the generator rotor key 1 .
• Install the generator rotor securely.
• Apply a small quantity of THREAD LOCK SUPER to the generator rotor nut 2 .
)
99000-32030: THREAD LOCK SUPER “1303”
• With the generator rotor locked using the special tool, tighten the generator rotor nut to the specified torque with a torque wrench.
%
09930-44530: Rotor holder
#
Generator rotor nut: 55 N·m (5.5 kgf-m)
DRIVESHAFT RETAINER
• Install the snap ring 3 to the driveshaft.
"
Use a new snap ring.
PRIMARY DRIVE GEAR AND OILPUMP DRIVE GEAR
Install the key
4
onto the crankshaft.
ENGINE 3-53
3-54 ENGINE
• Install the primary drive gear 1 and oil pump drive gear 2 .
NOTE:
Position the oil pump drive gear 2 , as shown in the illustration.
• Install the washer and primary drive gear/oil pump drive gear nut 3 .
NOTE:
This nut 3 has left hand threads.
• While holding the generator rotor with the special tool, tighten the primary drive gear/oil pump drive gear nut 3 to the specified torque with a torque wrench.
%
09930-44530: Rotor holder
#
Primary drive gear/oil pump drive gear nut:
50 N·m (5.0 kgf-m)
• Bend the lock washer securely.
GEARSHIFT
• Install each pawl into the gearshift cam driven gear.
1 Gearshift pawl
2 Pin
3 Spring
4 Gearshift cam driven gear
NOTE:
The large shoulder A must face to the outside.
• Install the gearshift cam driven gear assembly.
• Install the pawl lifter 1 and cam guide 2 .
NOTE:
Apply a small quantity of THREAD LOCK to the threads of the screws.
*
99000-32050: THREAD LOCK “1342”
• Install the return spring 3 to the gearshift shaft 4 .
• 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 to the oil pump mounting screws and tighten them.
*
99000-32050: THREAD LOCK “1342”
• Install the pin 5 .
• Install the oil pump driven gear 6 and E-ring 7 .
ENGINE 3-55
3-56 ENGINE
CLUTCH
1
Primary driven gear assembly
2
Clutch sleeve hub
3
Clutch push rod
4
Clutch driven plate
5
Clutch drive plate
6
Push piece
7
Clutch pressure plate
@
ITEM
A
N·m kgf-m
50 5.0
• Install the washer
1
and spacer
2
onto the countershaft.
NOTE:
Apply engine oil to the inside and outside surfaces of the spacer.
• Install the primary driven gear assembly 3 and washer 4 onto the countershaft.
NOTE:
When engaging the primary drive and driven gears, turn the primary driven gear assembly to the counterclockwise.
• Install the clutch sleeve hub 5 and lock washer 6 .
"
Install the lock washer so that its tongue A is aligned with the flat portion of the clutch sleeve hub.
• Install the clutch sleeve hub nut, and tighten it to the specified torque with the special tool.
#
Clutch sleeve hub nut: 50 N·m (5.0 kgf-m)
%
09920-53740: Clutch sleeve hub holder
• Bend the lock washer 1 securely.
• Install the clutch push rod 2 as shown in the illustration.
A Push piece side
• Apply engine oil to the bearing.
• Install the push piece 3 , bearing 4 and washer 5 .
• Install the clutch drive and driven plates one by one into the clutch sleeve hub.
• Install the clutch pressure plate 6 , clutch springs and clutch spring mounting bolts.
• Hold the generator rotor nut and tighten the clutch spring mounting bolts in a crisscross pattern.
NOTE:
Make sure that the clutch pressure plate is installed correctly.
• Loosen the lock nut 7 , and turn in the release screw 8 to feel resistance.
• From that position, turn out the release screw 8 ,
turn, and tighten the lock nut 7 by holding the release screw 8 .
ENGINE 3-57
3-58 ENGINE
CLUTCH COVER
• Install two dowel pins and new gasket 1 .
• Tighten the clutch cover bolts and oil filter cap nut securely.
"
* Install the new gasket washer to the bolt
A
.
* Install the clamp to the bolt B .
STARTER MOTOR
• Install the starter motor.
NOTE:
Apply grease to the O-ring.
(
99000-25010: SUZUKI SUPER GREASE “A”
.
"
Use a new O-ring to prevent oil leakage.
GENERATOR COVER
• Install the starter idle gear
2
, shaft and spacer.
• Install the dowel pin and new gasket 3 .
• Tighten the generator cover bolts securely.
ENGINE 3-59
PISTON/PISTON RING
• First, install a spacer 1 into the oil ring groove and then install two side rails
2
. 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.
"
When installing the spacer, be careful not to allow its two ends to overlap in the piston ring groove.
INCORRECT
CORRECT
• Install the 2nd ring and 1st ring.
NOTE:
1st ring and 2nd ring differ in shape.
1st
2nd
• The 1st and 2nd piston rings should be installed with their marks facing up.
1st ring
2nd ring
• 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
IN
• 1st ring
• Spacer
3-60 ENGINE
The followings are reminders for piston installation:
• Before installing the piston pin, apply molybdenum oil solution onto its surface.
• Apply molybdenum oil solution 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 1 .
.
'
MOLYBDENUM OIL SOLUTION
"
Use a new piston pin circlip 1 to prevent circlip failure.
• Install the piston with the arrow mark 2 facing towards the exhaust side.
CYLINDER
Before installing the cylinder, oil the big and small ends of the conrod and also the sliding surface of the piston.
• Install the dowel pins into the crankcase and then install the cylinder gasket 3 .
"
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
4
.
CYLINDER HEAD
• Install the dowel pins into the cylinder and then install the cylinder head gasket 5 onto the cylinder.
"
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 in the illustration.
A Copper washer
B Steel washer
• Tighten the cylinder head nuts to the specified torque in a crisscross pattern.
#
Cylinder head nut: Initial 10 N·m (1.0 kgf-m)
Final 23 N·m (2.3 kgf-m)
• Tighten the cylinder base nuts 1 and cylinder head nuts 2 to the specified torque.
#
Cylinder base nut 1 : 10 N·m (1.0 kgf-m)
Cylinder head nut 2 : 10 N·m (1.0 kgf-m)
CAMSHAFT
• Turn the crankshaft counterclockwise, and align the line A on the generator rotor with the mark B on the generator cover while keeping the cam chain tight.
"
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.
'
MOLYBDENUM OIL SOLUTION
IN.
ENGINE 3-61
EX.
3-62 ENGINE
• Install the C-ring 1 into the ring groove of the cylinder head.
• Align the engraved line marks A 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 B at just past top position.
NOTE:
Do not rotate the crankshaft while installing the camshaft or cam chain.
• Install the lock washer 2 so that it is covering the locating pin.
NOTE:
Apply a small quantity of THREAD LOCK SUPER 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: 11 N·m (1.1 kgf-m)
• Bend the lock washer securely.
2 Lock washer
3 Camshaft
4 Pin
5 Bolt
6 Camshaft sprocket
CYLINDER HEAD COVER
• Pour engine oil in each oil pocket in the cylinder head.
• Install the camshaft end cap
1
.
• Clean the mating surfaces of the cylinder head and head cover.
• Install the dowel pins.
• Apply SUZUKI BOND uniformly to the mating surface of the cylinder head cover and install it within a few minutes.
-
99000-31230: SUZUKI BOND “1216B”
NOTE:
When installing the cylinder head cover, the piston must be at the top dead center on the compression stroke.
ENGINE 3-63
• Tighten the cylinder head cover bolts to the specified torque with a torque wrench diagonally.
#
Cylinder head cover bolt: 10 N·m (1.0 kgf-m)
"
Install the gasket washer to the bolt A .
"
Be sure to check the valve clearance. (
!
2-5)
1216
3-64 ENGINE
CAM CHAIN TENSION ADJUSTER
Install the cam chain tension adjuster. Pay attention to the following points:
• Apply engine oil to the push rod.
• Turn the adjusting screw clockwise with a flat-bladed screw driver until the push rod locked.
• Fit a new gasket to the cam chain tension adjuster body.
"
Use a new gasket to prevent oil leakage.
• Install the cam chain tension adjuster body to the cylinder and tighten the bolts to the specified torque.
#
Cam chain tension adjuster bolt: 7 N·m (0.7 kgf-m)
• Turn the adjusting screw counterclockwise with a flat-bladed screw driver to unlock.
• Install the rubber cap.
PAIR (AIR SUPPLY) SYSTEM
PAIR HOSE
INSPECTION
• Inspect the PAIR hoses for wear or damage.
• Inspect the PAIR hoses are securely connected.
PAIR CONTROL VALVE
REMOVAL
• Disconnect the hoses and remove the PAIR control valve 1 .
INSPECTION
• Inspect that air flows through the PAIR control valve air inlet port A to the air outlet port B . If air does not flow out, replace the PAIR control valve with a new one.
• Connect the vacuum pump gauge to the vacuum port of the control valve as shown in the photograph.
• Apply negative pressure slowly to the control valve and inspect the air flow. If air does not flow out, the control valve and is in normal condition. If the control valve does not function, replace it with a new one.
$
Negative pressure range:
–37.3 – –60.0 kpa (–280 – –450 mmHg)
%
09917-47010: Vacuum pump gauge
"
Use a hand operated vacuum pump to prevent the control valve damage.
INSTALLATION
Installation is in the reverse order of the removal.
ENGINE 3-65
FUEL AND LUBRICATION SYSTEM 4-1
FUEL AND LUBRICATION SYSTEM
CONTENTS
CONSTRUCTION ...................................................................................4- 4
FLOAT HEIGHT ADJUSTMENT ............................................................4-10
FUEL LEVEL ADJUSTMENT ................................................................4-10
CARBURETOR HEATER INSPECTION ................................................4-11
CARBURETOR THERMO-SWITCH INSPECTION ...............................4-11
THROTTLE POSITION SENSOR INSPECTION ...................................4-11
REASSEMBLY AND REMOUNTING .....................................................4-12
ENGINE LUBRICATION SYSTEM ..................................................................4-14
ENGINE LUBRICATION SYSTEM CHART ...........................................4-14
2
4
6
4-2 FUEL AND LUBRICATION SYSTEM
FUEL TANK/FUEL VALVE
REMOVAL
!
Gasoline is highly flammable and explosive. Keep heat, spark and flame away.
• Remove the seat. (
"
5-3)
• Turn the fuel valve to “OFF” position and disconnect the fuel hose
1
from the fuel valve.
• 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.
REMOUNTING
!
Gasoline is very explosive. Extreme care must be taken. The gaskets ( 2 and 3 ) must be replaced with new ones to prevent fuel leakage.
• Remount the fuel valve and tank in the reverse order of removal.
FUEL AND LUBRICATION SYSTEM 4-3
4-4 FUEL AND LUBRICATION SYSTEM
CARBURETOR
CONSTRUCTION
1
Top cap
2
Spring
3
Spring retainer
4
Jet needle
5
Diaphragm
6
Piston valve
7
Throttle stop screw
8
Needle jet
9
Needle jet holder
0
Main jet
A
Pilot jet
B
Float
C
Needle valve
D
Float pin
E
Pilot screw
F
Gasket
G
Drain plug
H
Starter plunger
I
TPS
J
Carburetor heater
K
Thermo-switch
SPECIFICATIONS
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Pilot screw
Throttle cable play
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(P.S.)
I.D. NO. LOCATION
Carburetor has an I.D. number 1 on its body.
FUEL AND LUBRICATION SYSTEM 4-5
SPECIFICATION
MIKUNI BS26
26 mm
13GA
1 500 ± 100 r/min
17.1 ± 1.0 mm
# 115
4EJ44-2nd
P-0M
# 105
# 15
PRE-SET (2 turns out)
2.0 – 4.0 mm
REMOVAL
See page 3-4.
4-6 FUEL AND LUBRICATION SYSTEM
DISASSEMBLY
• Disconnect the fuel hose 1 , air vent hose 2 , vacuum hose
3 and carburetor overflow hose 4 .
• Remove the carburetor top cap 5 .
• Remove the spring 6 , diaphragm 7 and piston valve 8 .
• Remove the spring seat
9
.
• Remove the spring 0 , rings A , B and jet needle C .
• Remove the float chamber D .
• Remove the float pin 1 .
• Remove the floats 2 along with the needle valve 3 .
#
Do not use wire to clean the valve seat and jets.
• Remove the main jet 4 , needle jet holder 5 , needle valve seat
6
and pilot jet
7
.
FUEL AND LUBRICATION SYSTEM 4-7
• Remove the needle jet 8 .
• Remove the starter plunger
9
.
• 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.
#
Replace the plug with a new one.
Drill-stop
Pilot screw
Plug
Carburetor body
4-8 FUEL AND LUBRICATION SYSTEM
• Slowly turn the pilot screw 1 in clockwise and count the number of turns until the screw is lightly seated. Make a note of how many turns were made so the screw can be reset correctly after cleaning.
• Remove the pilot screw 2 , spring 3 , washer 4 and O-ring
5
.
NOTE:
Prior to disassembly, mark the sensor’s original position with a paint or scribe for accurate reinstallation.
• Remove the throttle position sensor
6
.
FUEL AND LUBRICATION SYSTEM 4-9
CLEANING
!
Some carburetor cleaning chemicals, especially diptype soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and storage.
• Clean all jets with a spray-type carburetor cleaner and blow dry with compressed air.
• Clean all circuits of the carburetor thoroughly - not just the perceived problem area. Clean the circuits in the carburetor body with a spray-type cleaner and allow each circuit to soak if necessary to loosen dirt and varnish. Blow the body dry with compressed air.
#
Do not use wire to clean jets or passageways. Wire can damage jets and passageways. If the components cannot be cleaned with a spray cleaner it may be necessary to use a dip-type cleaning solution and allow them to soak. Always follow the chemical manufacturer’s instructions for proper use and cleaning of the carburetor components.
• After cleaning, reassemble the carburetor with new seals and gaskets. Reinstall the pilot screw to the original factory setting with a new O-ring seal.
INSPECTION
Check following items for any damage or clogging.
* Pilot jet
* Main jet
* Main air jet
* Needle jet holder
* Pilot air jet
* Float
* Jet needle
* Needle jet
* Piston valve
* Piston valve diaphragm
NEEDLE VALVE INSPECTION
If foreign matter is caught between the valve seat and the needle, the gasoline will continue flowing and cause it to overflow. If the seat and needle are worn beyond the permissible limits, similar trouble will occur. Conversely, if the needle sticks, the gasoline will not flow into the float chamber. Clean the float chamber and float parts with gasoline. If the needle is worn as shown in the illustration, replace it together with a valve seat. Clean the fuel passage of the mixing chamber with compressed air.
CORRECT INCORRECT
4-10 FUEL AND LUBRICATION SYSTEM
FLOAT HEIGHT ADJUSTMENT
• To check the float height, invert the carburetor body, with the float arm kept free, measure the height A while float arm is just in contact with needle valve by using calipers.
$
Float height A : 17.1 ± 1.0 mm
%
09900-20102: Venier calipers
NOTE:
This data is approximate values for reference purpose.
• Bend the tongue 1 as necessary to bring the height A to this value.
FUEL LEVEL ADJUSTMENT
• Install the special tool to the carburetor overflow outlet 2 .
• Loosen the drain plug 3 .
%
09913-10760: Fuel level gauge
• Adjust the carburetor to the proper angle holding the body with a vice or the like.
Carburetor set position
Lateral direction: Horizontal
Longitudinal direction: See the illustration.
• Fill gasoline in the carburetor.
• Remove air completely from the fuel level gauge.
• With the level gauge held vertical, lower the gauge slowly and align the datum point with the gauge graduation. (See the illustration.)
• Wait until the fuel level stabilizes.
• Determine the zero point on the gauge graduation and after waiting again for level stabilization, measure the height B from the datum plane.
$
Fuel level B : 2.0 ± 1.0 mm below the datum point
!
This inspection must be performed in an area well ventilated, away from fire or sparks since gasoline, an explosive fluid, is used in this operation.
NOTE:
This data is approximate values for reference purpose.
12
FUEL AND LUBRICATION SYSTEM 4-11
NOTE:
The apparent fuel level measured in the level gauge is higher than the actual level in the float chamber because of meniscus effect. (Meniscus is approximately 1 mm.)
Datum point
Fuel level in gauge
CARBURETOR HEATER INSPECTION
• Disconnect the carburetor heater lead wires.
• Connect the positive + terminal of a 12 V battery to the terminal of the carburetor heater and the battery negative
-
terminal to the terminal.
• Check that the heater section A is heated in 5 minutes after the battery has been connected.
• Measure the resistance between the terminals.
%
09900-25008: Multi-circuit tester
$
Carburetor heater resistance: 12 – 18 Ω
CARBURETOR THERMO-SWITCH INSPECTION
• Cool the thermo-switch 1 with ice water and check for continuity.
%
09900-25008: Multi-circuit tester
$
Thermo-switch continuity: Below 8 – 14 °C Yes
Above 13 – 25 °C No
THROTTLE POSITION SENSOR INSPECTION
Measure the resistance between the terminals as shown in the illustration.
$
Throttle position sensor resistance: Approx. 5 k Ω
NOTE:
When performing this test, it is not necessary to remove the throttle position sensor.
4-12 FUEL AND LUBRICATION SYSTEM
REASSEMBLY AND REMOUNTING
Reassemble and remount the carburetor in the reverse order of disassembly and removal.
Pay attention to the following points:
#
* Assemble the parts taking consideration of their function.
* Replace O-rings and seals with new ones.
PILOT SCREW
• 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 the new plug 1 by tapping into its place with a punch.
Pilot screw
DIAGRAHM/PISTON VALVE
• When installing the piston valve, make sure the tab of the diaphragm is aligned with the concave section of the carburetor body’s rim.
Plug
1
Carburetor body
CARBURETOR HEATER
• Apply thermo-grease to the threads and tighten the carburetor heater.
&
99000-59029: THERMO-GREASE
'
Carburetor heater: 3 N·m (0.3 kgf-m)
THROTTLE POSITION SENSOR POSITIONING
• Install the throttle position sensor with the flats on the throttle shaft end securely engaged with the slot on the throttle position sensor.
• Measure the resistance
Ω
1 between the throttle position sensor terminals as shown in the illustration.
$
Throttle position sensor resistance
Ω 1 : Approx. 5 k Ω
• Measure the resistance Ω
2 between the throttle position sensor terminals as shown in the illustration.
• Fully open the throttle valve with the throttle lever.
• Position the throttle position sensor until resistance is approx. 3.09 – 4.63 k
Ω
.
Ω 2
• When the resistance Ω
2 is within specification, tighten the throttle position sensor mounting screws.
$
Throttle position sensor resistance Ω 2 :
Approx. 3.09 – 4.63 k
Ω
• After the assembly and installation on the engine have been completed, perform the following adjustment.
* Engine idle speed (
"
2-8)
* Throttle cable play (
"
2-8)
FUEL AND LUBRICATION SYSTEM 4-13
Ω
2
Ω
1
4-14 FUEL AND LUBRICATION SYSTEM
ENGINE LUBRICATION SYSTEM
ENGINE LUBRICATION SYSTEM CHART
CAMSHAFT
CAMSHAFT
JOURNAL (L)
CAM CHAIN
CAMSHAFT
JOURNAL (R)
CAM FACES
ROCKER ARM
SHAFTS
CONROD SMALL END
CYLINDER WALL
CONROD BIG
END BEARING
ORIFICE
DRIVESHAFT LEFT
SIDE BEARING
ORIFICE
CLUTCH RELEASE
CAM
COUNTERSHAFT
LEFT SIDE BEARING
COUNTERSHAFT
AND GEARS
PRIMARY DRIVEN
GEAR SPACER
DRIVESHAFT
AND GEARS
CLUTCH PLATES
CRANKSHAFT
OIL FILTER
BY-PASS
OIL PUMP
OIL SUMP
FILTER
OIL PRESSURE
(
"
2-23)
OIL FILTER
(
"
2-10)
OIL SUMP FILTER
(
"
3-45)
NOTE:
When separating the crankcase, wash the oil sump filter with cleaning solvent, and then blow compressed air through it to dry off solvent.
FUEL AND LUBRICATION SYSTEM 4-15
CHASSIS
CONTENTS
REMOVAL AND INSTALLATION ..........................................................5- 3
REMOVAL AND DISASSEMBLY ..........................................................5- 4
INSPECTION AND DISASSEMBLY ......................................................5- 5
BRAKE FLUID REPLACEMENT ...........................................................5-10
BRAKE PAD REPLACEMENT ..............................................................5-11
BRAKE CALIPER REMOVAL AND DISASSEMBLY ............................5-11
CALIPER INSPECTION .........................................................................5-13
CALIPER REASSEMBLY ......................................................................5-13
CALIPER REMOUNTING .......................................................................5-14
BRAKE DISC INSPECTION ...................................................................5-14
MASTER CYLINDER REMOVAL AND DISASSEMBLY .......................5-15
MASTER CYLINDER INSPECTION ......................................................5-16
MASTER CYLINDER REASSEMBLY AND REMOUNTING .................5-16
REMOVAL AND DISASSEMBLY ..........................................................5-20
REASSEMBLY AND REMOUNTING .....................................................5-24
REMOVAL AND DISASSEMBLY ..........................................................5-28
REASSEMBLY AND REMOUNTING .....................................................5-32
INSPECTION AND DISASSEMBLY ......................................................5-35
REASSEMBLY AND REMOUNING .......................................................5-36
REMOVAL AND DISASSEMBLY ..........................................................5-38
REAR BRAKE PEDAL REMOVAL ........................................................5-40
REAR BRAKE PEDAL INSTALLATION ...............................................5-41
CHASSIS 5-1
5
5-2 CHASSIS
CHASSIS
CONTENTS
REAR SHOCK ABSORBER ......................................................................... 5-42
REASSEMBLY AND REMOUNTING .................................................... 5-44
REAR SHOCK ABSORBER DISPOSAL .............................................. 5-45
INSPECTION AND REPLACEMENT .................................................... 5-47
SWINGARM PIVOT SHAFT INSTALLATION ....................................... 5-49
FINAL INSPECTION AND ADJUSTMENT ........................................... 5-49
TIRE INSTALLATION ............................................................................ 5-51
EXTERIOR PARTS
REMOVAL AND INSTALLATION
SEAT
• Remove the bolts (left and right).
• Remove the seat by taking off the fastener
1
.
LEFT FRAME COVER
• Remove the screw.
• Remove the left frame cover.
✩
: Hooked part
RIGHT FRAME COVER
• Remove the screw.
• Remove the right frame cover.
✩
: Hooked part
INSTALLATION
Install the seat and frame covers in the reverse order of removal.
CHASSIS 5-3
5-4 CHASSIS
FRONT WHEEL
ITEM
A
B
C
N · m kgf-m
65 6.5
23
4.5
2.3
0.45
REMOVAL AND DISASSEMBLY
• Raise the front wheel off the ground with a jack.
!
When using a jack, take care not to cause scratches on the chassis.
• Disconnect the speedometer cable
1
.
• Loosen the front axle pinch bolt 2 .
• Loosen the front axle 3 by using the special tool.
"
09900-18710: Hexagon socket (12 mm)
!
Do not operate the brake lever during or after front wheel removal.
1
Collar
2
Bearing
3
Front axle spacer
4
Bearing
5
Brake disc
6
Speedometer gearbox
7
Balancer weight
A
Front axle
B
Brake disc bolt
C
Spoke nipple
• Remove the brake disc by removing its bolts.
INSPECTION AND DISASSEMBLY
SPEEDOMETER GEARBOX
Turn the speedometer gear and check to see that the gear turns smoothly together with the speedometer pinion.
WHEEL (
#
2-18)
SPOKE NIPPLE (
#
2-19)
WHEEL BEARINGS
Inspect the play of the wheel bearings by finger while they are in the wheel.
Rotate the inner race by finger to inspect for abnormal noise and smooth rotation.
Replace the bearing in the following procedure if there is anything unusual.
CHASSIS 5-5
5-6 CHASSIS
• Remove the wheel bearings by using the special tool.
!
09921-20240: Bearing remover set
"
Replace the removed bearing with a new one.
AXLE SHAFT
Measure the front axle runout using the dial gauge.
If the runout exceeds the service limit, replace the front axle.
#
Front axle runout
Service Limit: 0.25 mm
!
09900-20606: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
09900-21304: V-block set (100 mm)
TIRE (
$
5-50)
REMOUNTING
Reassemble and remount the front wheel in the reverse order of removal and disassembly. Pay special attention to the following points:
WHEEL BEARINGS
• Apply SUZUKI SUPER GREASE to the bearings before installing.
%
99000-25010: SUZUKI SUPER GREASE “A”
• Install the wheel bearings using the special tools as described below.
!
09941-34513: Bearing installer set
"
* First install the right wheel bearing, then install the left wheel bearing.
* The sealed cover on the bearings must face to the outside.
Clearance
BRAKE DISC
• Apply THREAD LOCK SUPER to the brake disc bolts.
• Tighten the bolts to the specified torque.
&
99000-32130: THREAD LOCK SUPER “1360”
'
Brake disc bolt: 23 N·m (2.3 kgf-m)
(
Keep the brake disc clean, free from dirt and grease.
CHASSIS 5-7
5-8 CHASSIS
SPEEDOMETER GEARBOX
• Apply SUZUKI SUPER GREASE to the speedometer gearbox.
!
99000-25010: SUZUKI SUPER GREASE “A”
• Align the lugs 1 on the speedometer gearbox with the recesses 2 on the front wheel.
FRONT WHEEL
• Make sure that the stopper
3
on the front fork and the speedometer gearbox protrusion 4 are installed as shown.
"
When installing the front wheel, position the brake disc between the brake pads. Be careful not to damage the brake pads.
• Tighten the front axle to the specified torque.
• Tighten the front axle pinch bolt 5 to the specified torque.
#
09900-18710: Hexagon socket (12 mm)
$
Front axle: 65 N·m (6.5 kgf-m)
Front axle pinch bolt: 23 N·m (2.3 kgf-m)
NOTE:
* Before tightening the front axle pinch bolt
5
, move the front fork up and down four or five times.
* After remounting the front wheel, pump the brake lever a few times to check for proper brake operation.
FRONT BRAKE
CHASSIS 5-9
ITEM
A
B
C
D
N · m kgf-m
10
23
39
7.5
1.0
2.3
3.9
0.75
1
Cap
2
Diaphragm
3
Master cylinder
4
Piston set
5
Brake hose
6
Caliper holder
7
Caliper
8
Pad set
9
Piston
0
Piston and dust seal
A
Master cylinder mounting bolt
B
Brake hose union bolt
C
Brake caliper mounting bolt
D
Air bleeder valve
(
* This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use mix different types of fluid such as silicone-based or petroleum-based.
* Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or stored for long periods.
* When storing the brake fluid, seal the container completely and keep away from children.
* When replenishing brake fluid, take care not to get dust into fluid.
* When washing brake components, use fresh 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 neutral detergent.
!
Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials etc. and will damage then severly.
5-10 CHASSIS
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.
• Connect a clear hose to the air bleeder valve 1 and insert the other end of the hose into a receptacle.
• Loosen the air bleeder valve and pump the brake lever until the old brake fluid is completely out of the brake system.
• Close the air bleeder valve and disconnect a clear hose. Fill the reservoir with new brake fluid to the upper end of the inspection window.
)
Specification and classification: DOT 4
!
* Never reuse the brake fluid left over from previous servicing and which has been stored for long periods of time.
* Bleed air from the brake system. (
#
2-15)
BRAKE PAD REPLACEMENT
• Remove the brake caliper.
• Remove the pin 1 .
• Remove the brake pad mounting pin
2
and brake pads
3
.
!
* Do not operate the brake lever after brake pad removal.
* Replace the brake pad as a set, otherwise braking performance will be adversely affected.
• Install the new brake pads.
• Tighten the brake caliper mounting bolts to the specified torque.
'
Brake caliper mounting bolt: 39 N·m (3.9 kgf-m)
NOTE:
After replacing the brake pads, pump the brake lever a few times to check for proper brake operation and then check the brake fluid level.
BRAKE CALIPER REMOVAL AND
DISASSEMBLY
• Remove the brake hose union bolt 1 .
NOTE:
Place a rag underneath the union bolt on the brake caliper to catch any spilt brake fluid.
!
Immediately wipe off any brake fluid contacting any part of the motorcycle. The brake fluid reacts chemically with paint, plastics, rubber materials, etc., and will damage them severely.
• Remove the brake caliper.
CHASSIS 5-11
5-12 CHASSIS
• Remove the brake pads. (
#
5-11)
• Remove the brake caliper holder 2 .
• Remove the pad spring 3 .
• Remove the rubber parts
4
.
!
Do not use high pressure air to prevent piston damage.
• Remove the dust seal 5 and piston seal 6 .
!
Do not reuse the removed dust seals and piston seals to prevent fluid leakage.
CALIPER INSPECTION
Inspect the caliper cylinder wall and piston surface for scratch, corrosion or other damages.
If any abnormal condition is noted, replace the caliper assembly with a new one.
CALIPER REASSEMBLY
Reassemble and remount the brake caliper in the reverse order of removal and disassembly. Pay special 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.
!
* Wash the brake caliper components with new brake fluid before reassembly. Do not wipe the brake fluid off after washing the components with rag.
* Replace the removed piston seals and dust seals with new ones. Apply brake fluid to all of the seals, brake caliper bores and pistons before reassembly.
)
Specification and classification: DOT 4
PISTON SEALS
• Install the piston seal 1 and dust seal 2 as shown.
RUBBER PARTS
• Replace the removed rubber parts with new ones.
CHASSIS 5-13
5-14 CHASSIS
BRAKE CALIPER HOLDER
• Apply SUZUKI SILICON GREASE to the brake caliper holder pin.
*
99000-25100: SUZUKI SILICONE GREASE
CALIPER REMOUNTING
• Tighten the brake caliper mounting bolts
1
.
'
Brake caliper mounting bolt: 39 N·m (3.9 kgf-m)
• With the hose and contacted to the stopper 2 , tighten the union bolt 3 .
'
Brake hose union bolt: 23 N·m (2.3 kgf-m)
• Fill the system with brake fluid and bleed air. (
#
2-14)
BRAKE DISC INSPECTION
Check the brake disc for cracks or damage and measure the thickness using the micrometer.
If any damages are found or if the thickness is less than the service limit, replace the brake disc with a new one. (
#
5-4)
$
Brake disc thickness
Service Limit: 3.5 mm
"
09900-20205: Micrometer (0 – 25 mm)
• Measure the runout with a dial gauge.
• If either measurement exceeds the service limit, replace the brake disc with a new one. (
#
5-4)
$
Brake disc runout
Service Limit: 0.30 mm
"
09900-20606: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
MASTER CYLINDER REMOVAL AND
DISASSEMBLY
• Place a rag underneath the brake hose union bolt 1 on the master cylinder to catch any spilt brake fluid. (
#
5-10)
!
Immediately wipe off any brake fluid contacting any part of the motorcycle. The brake fluid reacts chemically with paint, plastics, rubber materials, etc., and will damage them severely.
• Remove the rear view mirror (right) 2 .
• Disconnect the front brake light switch lead wire coupler 3 .
• Remove the front brake master cylinder 4 .
• Remove the brake switch
5
and brake lever
6
.
• Remove the reservoir cap 7 and diaphragm 8 .
CHASSIS 5-15
5-16 CHASSIS
• Pull out the dust seal boot 1 and remove the snap ring 2 .
• Remove the piston 3 and spring 4 .
MASTER CYLINDER INSPECTION
Inspect the master cylinder bore for any scratches or damage. If any damages are found, replace the master cylinder with a new one.
MASTER CYLINDER 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 master cylinder components with new brake fluid before reassembly.
* Do not wipe the brake fluid off after washing the components with rag.
* 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
• Install the piston/cup set.
• When installing the brake light switch, align the projection on the switch with the hole in the master cylinder.
CHASSIS 5-17
Boot
Spring Piston
Primary cup
Snap ring
Secondary cup
• When remounting the master cylinder on the handlebars, align the master cylinder holder’s mating surface with the punched mark A on the handlebars, and then tighten the upper clamp bolt first.
'
Master cylinder bolt: 10 N·m (1.0 kgf-m)
• Install the brake hose union as shown and tighten the union bolt to the specified torque.
'
Brake union bolt: 23 N·m (2.3 kgf-m)
• Fill the master cylinder with brake fluid and bleed air.
(
#
2-14)
Upper clamp bolt
Master cylinder
Handlebar
Punch mark
Clearance
5-18 CHASSIS
HANDLEBARS
1
Handlebars
2
Balancer cap
3
Right grip
4
Front brake lever
5
Front brake switch
6
Left grip
7
Clutch lever
8
Clutch switch
REMOVAL
HANDLEBAR LEFT SIDE PARTS
• Remove the rear view mirror 1 .
• Disconnect the clutch lever position switch coupler 2 .
• Remove the left handlebar switch box
3
.
• Remove the left handlebar balancer 4 .
• Remove the left grip 5 .
• Remove the clutch lever holder
6
.
HANDLEBAR RIGHT SIDE PARTS
• Remove the rear view mirror 1 .
• Disconnect the front brake light switch coupler 2 .
• Remove the front brake master cylinder 3 .
• Remove the right handlebar balancer 4 .
• Remove the handlebar right switch box 5 .
• Disconnect the throttle cable and remove the throttle grip 6 .
• Remove the handlebars by removing the handlebar clamp bolts.
CHASSIS 5-19
REMOUNTING
Remount the handlebars in the reverse order of removal. Pay special attention to the following points:
• When setting the handlebar clamp to the handlebar holder of the steering upper bracket, face the punched mark A on its clamp forward.
• Install the handlebars with the punch mark B aligned with the handlebar clamp as shown.
• First, tighten the handlebar clamp bolts 1 to the half of specified torque, and then tighten the handlebar clamp bolts 1 and
2 to the specified torque.
'
Handlebar clamp bolt: 23 N·m (2.3 kgf-m)
Front
Punch mark
Clearance
• Apply grease to the throttle cables and assemble them to the pulley.
%
99000-25010: SUZUKI SUPER GREASE “A”
• With the stopper 3 engaged with the handlebar hole, assemble the handlebar switch.
• Install the brake master cylinder. (
#
5-17)
• Align the mating face of clutch lever holders with the punch mark C and tighten the bolt.
• With the stopper 4 engaged with the handlebar hole, assemble the left handlebar switch.
5-20 CHASSIS
FRONT FORK
1
O-ring
2
Spacer
3
Washer
4
Front fork spring
5
Damper rod
6
Rebound spring
7
Inner tube
8
Oil lock piece
9
Dust seal
0
Oil seal stopper ring
A
Oil seal
B
Outer tube
A
Front fork cap bolt
B
Front axle pinch bolt
C
Damper rod bolt
ITEM
A
B
C
N · m kgf-m
23 2.3
23
30
2.3
3.0
REMOVAL AND DISASSEMBLY
• Remove the front wheel. (
#
5-4)
• Remove the front fender 1 .
• Loosen the front fork upper clamp bolt 2 .
NOTE:
Slightly loosen the front fork cap bolt 3 before loosening the lower clamp bolt to facilitate later disassembly.
• Loosen the front fork lower clamp bolt 4 .
NOTE:
Hold the front fork by the hand to prevent sliding out of the steering stem.
• Loosen and remove the front fork cap bolt 5 .
(
Take care so that the cap bolt does not spring out by the force of the spring.
• Remove the spacer
6
, washer
7
and spring
8
.
• 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.
CHASSIS 5-21
5-22 CHASSIS
• Remove the damper rod bolt using a 6-mm hexagon wrench and the special tools.
"
09940-34520: “T” handle
09940-34561: Attachment “D”
• Remove the damper rod 1 and rebound spring 2 .
• Remove the dust seal 3 and the oil seal stopper ring 4 .
!
Oil seal and dust seal must be replaced with the new ones when assembling the front fork.
• Pull the inner tube out of the outer tube.
• Remove the oil lock piece 5 .
• Remove the oil seal by using the special tool.
"
09913-50121: Oil seal remover
INSPECTION
INNER AND OUTER TUBE
Inspect the inner tube sliding surface and outer tube sliding surface for any scuffing or damage.
FRONT FORK SPRING
Measure the fork spring free length. If the fork spring free length is shorter than the service limit, replace the fork spring with a new one.
$
Front fork spring free length
Service limit: 375 mm
DAMPER ROD RING
Inspect the damper rod ring for wear or damage. If it is worn or damaged, replace it with a new one.
CHASSIS 5-23
5-24 CHASSIS
REASSEMBLY AND REMOUNTING
Reassemble and remount the front fork in the reverse order of removal and disassembly. Pay attention to the following points:
!
* Thoroughly wash all the component parts being assembled.
* When reassembling the front fork, use new fork oil.
* Use the specified fork oil for the front fork.
* When reassembling, replace the oil seal, dust seal and damper rod bolt gasket with new ones.
• Insert the oil lock piece 1 into the inner tube and install the oil seal 2 .
NOTE:
Apply grease to the oil seal 2 lip lightly before installing it.
%
99000-25010: SUZUKI SUPER GREASE “A”
NOTE:
* When installing the oil lock piece, insert the tapered end A of oil lock piece into the inner tube.
* When inserting the inner tube into the outer tube, take care not to come off the oil lock piece from the inner tube.
OIL SEAL
• Apply fork oil to the lip of the oil seal 1 and install it into the outer tube using the front fork oil seal installer.
"
09940-52861: Front fork oil seal installer set
!
Wash clean the front fork oil seal installer before using. If dirt is on the installer, the inner tube may possibly be damaged during press-fitting work.
• Install the oil seal stopper ring 2 and dust seal 3 .
!
Make sure that the oil seal stopper ring is fitted securely.
DAMPER ROD
• Fit the rebound spring 1 to the damper rod 2 and install them to the inner tube.
• Fit the gasket 3 , coat the damper rod bolt 4 with the thread lock and tighten the bolt to the specified torque.
'
Damper rod bolt: 30 N·m (3.0 kgf-m)
+
99000-32050: THREAD LOCK “1322”
"
09940-34520: “T” handle
09940-34561: Attachment “D”
!
Use a new damper rod bolt gasket 3 to prevent oil leakage.
CHASSIS 5-25
5-26 CHASSIS
FORK OIL
• Pour the specified fork oil into the inner tube.
$
Front fork oil capacity (each leg): 230 ml
,
99000-99044-10G: SUZUKI FORK OIL #10 or equivalent fork oil
• Hold the front fork leg in a vertical position and adjust the fork oil level by using the special tool.
• When adjusting the oil level, remove the fork spring and compress the inner tube fully.
$
Front fork oil level (without spring): 171.0 mm
"
09943-74111: Fork oil level gauge
FORK SPRING
The end of the fork spring with the smaller pitch A should be at the top of the front fork.
• Fit the O-ring to the front fork cap bolt and apply grease.
%
99000-25010: SUZUKI SUPER GREASE “A”
!
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.
A
• Tighten the front fork lower clamp bolt 1 and front fork cap bolt 2 to the specified torque.
• Tighten the front fork upper clamp bolt 3 to the specified torque.
'
Front fork upper clamp bolt: 23 N·m (2.3 kgf-m)
Front fork lower clamp bolt: 33 N·m (3.3 kgf-m)
Front fork cap bolt: 23 N·m (2.3 kgf-m)
• Install the front fender and tighten the mounting bolts temporarily.
• Install the front brake caliper. (
#
5-14)
• Install the front wheel. (
#
5-8)
• Move the front fork up and down several times, and tighten the front fender mounting bolts securely.
!
* After assembling the front fork, check each tightening part for looseness, play and other conditions.
* Check for oil leakage.
CHASSIS 5-27
5-28 CHASSIS
STEERING
1
Steering stem upper bracket
2
Dust seal
3
Upper inner race
4
Steering stem upper bearing
5
Lower inner race
6
Steering stem lower bearing
A
Steering stem head nut
B
Front fork upper clamp bolt
C
Steering stem nut
D
Front fork lower clamp bolt
ITEM
A
B
C
D
N · m kgf-m
90 9.0
23
45
33
2.3
4.5
3.3
REMOVAL AND DISASSEMBLY
• Remove the front wheel. (
#
5-4)
• Remove the front fork. (
#
5-20)
• Remove the brake hose guide 1 .
• Remove the headlight.
• Disconnect the headlight and position light couplers.
• Remove the headlight housing 2 .
• Remove the speedometer 3 .
• Remove the front turn signal lights
4
,
5
.
• Remove the handlebar switch harness.
CHASSIS 5-29
5-30 CHASSIS
• Remove the handlebars 6 .
!
Protect the removed handlebars with a cloth to prevent it touching other parts directly.
• Remove the steering stem head nut 7 .
!
The steering stem head may rotate together and damage the fuel tank. Use a cloth or the like to prevent such damage.
• Remove the steering stem nut 8 using the special tool.
• Draw out the steering stem lower bracket 9 .
"
09940-14911: Steering stem nut socket wrench
NOTE:
Hold the steering stem bracket by hand to prevent it from falling.
• Remove the dust seal
0
and upper bearing inner race
A
.
• Remove the steering stem upper bearing B .
• Remove the steering stem lower bearing C .
• Remove the ignition switch D using the special tools.
"
09930-11920: Torx bit JT40H
09930-11940: Bit holder
INSPECTION
Inspect the removed parts for the following abnormalities. If any damages are found, replace the respective parts with the new ones.
* Steering race wear and brinelling
* Bearing wear or damage
* Abnormal bearing noise
* Distortion of steering stem or handlebars
• Remove the steering stem lower inner race, use a chisel.
!
* Unless corrosion, damage or other abnormal condition is found, the bearing race need not be replaced.
* Once the lower inner race has been removed, replace it with a new one.
• Drive out the steering stem upper and lower bearing races by using the special tools.
"
09941-54911: Bearing outer race remover
09941-74911: Steering bearing remover
CHASSIS 5-31
5-32 CHASSIS
REASSEMBLY AND REMOUNTING
Reassemble and remount the steering stem in the reverse order of removal and disassembly. Pay attention to the following points:
OUTER RACES
• Press in the upper and lower outer races by using the special tool.
"
09941-34513: Steering outer race installer
BEARINGS
• Press in the steering stem lower race using the special tool.
"
09941-74911: Steering bearing installer
• Apply SUZUKI SUPER GREASE to the steering stem upper and lower bearings.
%
99000-25010: SUZUKI SUPER GREASE “A”
• Install the bearings
1
, inner race
2
and the dust seal
3
.
STEERING STEM
• Tighten the steering stem nut to the specified torque by using the special tools.
'
Steering stem nut: 45 N·m (4.5 kgf-m)
"
09940-14911: Steering stem nut socket wrench
NOTE:
The flange side of the steering stem nut must face down.
• Turn the steering stem bracket about five or six times to the left and right so that the bearings seat properly.
• Loosen the steering stem nut ¼ – ½ of a turn.
• In this condition, check that the steering stem can turn smoothly with no rattle and stiffness.
• If there is a rattle or heavy movement, adjust the tightness by the stem nut.
NOTE:
This adjustment will vary from motorcycle to motorcycle.
• Before tightening the steering stem head nut, temporarily install the front forks.
• Tighten the steering stem head nut 1 to the specified torque.
'
Steering stem head nut: 90 N·m (9.0 kgf-m)
• Install the front forks. (
#
5-26)
• Install the handlebars. (
#
5-19)
• Install the speedometer.
• Install the headlight housing and headlight.
• Pass the turn signal lead wires 2 and speedometer cable 3 through the guides 4 .
• Install the front wheel. (
#
5-8)
!
Check that the cable or wire harness does not prevent the handle operation.
CHASSIS 5-33
¼ – ½ turn
5-34 CHASSIS
REAR WHEEL
1
Rear axle
2
Rear sprocket
3
Spacer
4
Bearing (Right)
5
Collar
6
Rear wheel
7
Bearing (Left)
8
Brake cam lever
9
Brake panel
0
Brake cam
A
Brake shoe
B
Return spring
A
Rear axle nut
B
Rear sprocket mounting nut
C
Rear brake cam lever nut
ITEM
A
B
C
N · m kgf-m
65 6.5
60
7
6.0
0.7
REMOVAL
• Remove the drive chain cover 1 .
• Remove the rear brake adjuster nut 2 , spring 4 washer 5 and pin 3 .
• Remove the rear axle nut 6 .
• Raise the rear wheel off the ground with a jack or wooden block.
• Loosen the drive chain adjusters 7 , left and right.
• Remove the rear axle 8 .
• Disengage the drive chain from the rear sprocket.
• Remove the rear wheel.
• Remove the rear brake panel 9 .
• Remove the rear sprocket 0 .
• Remove the bearings by using the special tool.
"
09921-20240: Bearing remover set, or
09941-50111: Wheel bearing remover
!
The removed bearing should be replaced with a new one.
INSPECTION AND DISASSEMBLY
WHEEL BEARINGS.....................................................................
#
5-6
REAR AXLE SHAFT ...............................................................
#
5-6
WHEEL ...................................................................................
#
2-18
SPOKE NIPPLES ........................................................................
#
2-19
TIRE ........................................................................................
#
2-18
CHASSIS 5-35
5-36 CHASSIS
REAR SPROCKET
Inspect the rear sprocket teeth for wear.
If they are worn, replace the sprocket and drive chain.
REASSEMBLY AND REMOUNING
Reassemble and remount the rear wheel and rear brake in the reverse order of removal and disassembly. Pay attention to the following points:
WHEEL BEARINGS
• Apply SUZUKI SUPER GREASE to the bearings before installing.
%
99000-25010: SUZUKI SUPER GREASE “A”
• Install the wheel bearings using the special tool.
"
09941-34513: Bearing installer set
!
* First install the right wheel bearing, then install the left wheel bearing.
* The sealed cover on the bearing must face out.
Normal wear Excessive wear
Clearance
REAR SPROCKET
• Tighten the sprocket mounting nuts to the specified torque.
'-
Rear sprocket mounting nut: 60 N·m (6.0 kgf-m)
NOTE:
The stamped mark A on the rear sprocket should face to the outside.
REAR WHEEL
• Align the brake panel stopper 1 on the swingarm with the recess on the brake panel.
• Install the rear axle shaft.
• Adjust the drive chain slack after installing the rear wheel.
(
#
2-12)
• Tighten the rear axle nut 2 to the specified torque.
'
Rear axle nut: 65 N·m (6.5 kgf-m)
• Tighten both chain adjusters 3 securely.
• Adjust the rear brake pedal free travel. (
#
2-16)
CHASSIS 5-37
5-38 CHASSIS
REAR BRAKE
1
Brake shoe
2
Cam lever bolt
3
Brake cam lever
4
Brake cam
5
Spring
6
Push rod
REMOVAL AND DISASSEMBLY
• Remove the rear wheel. (
#
5-34)
• Remove the rear brake panel 1 .
• Remove the brake shoes 2 , 3 from the brake panel.
• Remove the brake cam lever nut 4 .
• Remove the brake cam lever 5 .
• Remove the rear brake cam 6 .
• Remove the washer 7 and O-ring 8 .
INSPECTION
BRAKE DRUM
Inspect the brake drum and measure the brake drum I.D. to determine the extent of wear.
Replace the brake drum if the measurement exceeds the service limit. The value of this limit is indicated inside the brake drum.
$
Brake drum I.D.
Service Limit: 110.7 mm
BRAKE SHOES
Check the brake shoe wear and decide whether it should be replaced or not.
Replace two brake shoes together as a set.
!
Replace the brake shoes as a set, otherwise braking performance will be adversely affected.
BRAKE CAM
Inspect the brake cam for abnormal wear.
Place the brake cam into the brake panel and check for smooth rotation.
Check that the rotating parts are coated with sufficient grease.
REASSEMBLY
• When installing the brake camshaft, apply SUZUKI SUPER
GREASE to the camshaft, cam face and pin.
%
99000-25010: SUZUKI SUPER GREASE “A”
CHASSIS 5-39
5-40 CHASSIS
• Install the brake shoes with spring hooks faced inside.
!
Be careful not to apply too much grease to the cam and pin. If grease gets on the lining, brake slippage will result.
• When installing the brake cam lever, align the groove A of camshaft with slit of cam lever.
• Tighten the brake cam lever nut to the specified torque.
'
Brake cam lever nut: 7 N·m (0.7 kgf-m)
• Install the rear wheel. (
#
5-37)
REAR BRAKE PEDAL REMOVAL
• Remove the rear brake adjuster nut 1 , pin 2 , spring 3 and washer 4 .
• Remove the rear brake light switch spring
5
.
• Remove the brake pedal return spring 6 .
• Remove the snap ring 7 .
• Remove the brake pedal.
REAR BRAKE PEDAL INSTALLATION
Install the rear brake pedal in the reverse order of removal. Pay attention to the following points:
• Apply grease to the brake pedal shaft.
%
99000-25010: SUZUKI SUPER GREASE “A”
• After assembling, check the brake for operating condition, play and braking effect.
• Check the brake lamp lighting timing.
CHASSIS 5-41
5-42 CHASSIS
REAR SHOCK ABSORBER
1
Rear shock absorber
A
Rear shock absorber bolt
B
Rear shock absorber bolt and nut
ITEM
A
B
N · m kgf-m
50 5.0
50 5.0
REMOVAL
• Remove the rear wheel. (
#
5-34)
• Remove the rear shock absorber lower nut and bolt.
• Remove the rear shock absorber upper bolt.
• Remove the rear shock absorber.
• Remove the spacer 1 .
• Remove the dust seals 2 .
INSPECTION
Inspect the spacer for any flaws or other damage. If any damages are found, replace the spacer with a new one.
Inspect the shock absorber body and bushing for damage and oil leakage. If any defects are found, replace the shock absorber with a new one.
!
Do not attempt to disassemble the rear shock absorber. It is unserviceable.
CHASSIS 5-43
5-44 CHASSIS
REASSEMBLY AND REMOUNTING
• Apply grease to the spacer.
%
99000-25010: SUZUKI SUPER GREASE “A”
• Install the dust seal taking care about its direction.
Outside Inside
• Install the rear shock absorber facing the stamp A forward.
• Tighten the rear shock absorber upper mounting bolt and lower mounting nut to the specified torque.
'
Rear shock absorber upper bolt: 50 N·m (5.0 kgf-m)
Rear shock absorber lower nut: 50 N·m (5.0 kgf-m)
• Install the rear wheel. (
#
5-37)
CHASSIS 5-45
REAR SHOCK ABSORBER DISPOSAL
(
* The rear shock absorber unit contains high-pressure nitrogen gas.
* Mishandling can cause explosion.
* Keep away from fire and heat. High gas pressure caused by heat can cause an explosion.
* Release gas pressure before disposing.
GAS PRESSURE RELEASE
• Mark the drill hole with a center punch.
40 mm
Mark
• Cover the rear shock absorber with a transparent plastic bag
1 .
• Hold the shock absorber 2 with a vice.
• Make a hole with a drill.
(
* When making a hole, oil may spring out. Be sure to wear protective goggles or the like to protect your eyes.
* Do not bring your face close to the hole position to avoid the oil from splashing to your face or mouth.
5-46 CHASSIS
SWINGARM
1
Pivot shaft
2
Dust cover
3
Washer
4
Dust seal
5
Bushing
6
Collar
A
Swingarm pivot nut
ITEM
A
N · m kgf-m
65 6.5
REMOVAL
• Remove the rear wheel. (
#
5-34)
• Remove the rear shock absorber lower mounting nut and bolt.
• Remove the swingarm pivot nut and shaft.
• Remove the swingarm assembly.
• Remove the dust seal covers 1 and collars 2 .
• Remove the chain buffer 3 .
• Remove the dust seals
4
.
INSPECTION AND REPLACEMENT
SWINGARM
Inspect the swingarm for damage. If any damages are found, replace the swingarm with a new one.
CHASSIS 5-47
5-48 CHASSIS
CHAIN BUFFER
Inspect the chain buffer for damage. If any damages are found, replace the chain buffer with a new one.
SWINGARM PIVOT SHAFT
Measure the pivot shaft runout using the dial gauge. If the runout exceeds the service limit, replace the pivot shaft.
$
Swingarm pivot shaft runout
Service limit: 0.6 mm
"
09900-20606: Dial gauge
09900-20701: Magnetic stand
09900-21304: V-block
SWINGARM PIVOT BUSHING
Insert the collars into the swingarm bushings, move the collar up and down and check for any play. If there is excessive play, replace the bushings with new ones.
SWINGARM PIVOT BUSHING REPLACEMENT
• Remove the swingarm bushings by using the special tools.
"
09923-74510: Bearing remover
09930-30102: Sliding shaft
• Press the swingarm bushings into the swingarm pivot by using the special tool and suitable size socket wrench 1 .
"
09924-84521: Bearing installer
NOTE:
Press the swingarm bushings at 8 mm depth from the swingarm edge. (
#
5-49)
CHASSIS 5-49
• Press the dust seals into the swingarm pivot by using the special tool and suitable size socket wrench 2 .
"
09924-84521: Bearing installer
NOTE:
Press the swingarm dust seals at 5 mm depth from the swingarm edge.
SWINGARM PIVOT SHAFT INSTALLATION
REMOUNTING
Remount the rear swingarm and suspension in the reverse order of removal. Pay attention to the following points:
• Tighten the swingarm pivot nut to the specified torque.
'
Swingarm pivot nut: 65 N·m (6.5 kgf-m)
• Install the rear shock absorber. (
#
5-44)
• Install the rear wheel. (
#
5-37)
FINAL INSPECTION AND ADJUSTMENT
After installing the rear suspension and wheel, the following adjustments are required before driving.
* Drive chain (
#
2-12)
* Rear brake (
#
2-16)
* Chassis bolts and nuts (
#
2-20)
* Rear suspension (
#
2-19)
5 mm
Bushing
8 mm
65 N.m
(6.5 kgf-m)
5-50 CHASSIS
TIRE AND WHEEL
TIRE REMOVAL
Tube tire is used for this model. When removing or installing the tire, be careful not to damage the tube.
For operating procedures, refer to the instructions supplied by the tire changer manufacturer.
NOTE:
When removing the tire in the case of repair or inspection, mark the tire with a chalk to indicate the tire position relative to the valve position.
Even though the tire is refitted to the original position after repairing puncture, the tire may have to be balanced again since such a repair can cause imbalance.
INSPECTION
WHEEL
Wipe the wheel clean and check for the following:
• Distortion and crack
• Any flaws and scratches at the bead seating area
• Wheel rim runout (
#
2-18)
TIRE
Tire must be checked for the following points:
• Nick and rupture on side wall
• Tire tread depth (
#
2-18)
• Tread separation
• Abnormal, uneven wear on tread
• Surface damage on bead
• Localized tread wear due to skidding (Flat spot)
• Abnormal condition of inner liner
TUBE
• Inspect the tube after the tire is removed from the rim.
• If the tube has abnormality, replace the tube with a new one.
TIRE INSTALLATION
• Apply tire lubricant to the tire bead.
!
Do not use oil, grease or gasoline on the tire bead in place of tire lubricant.
• Install the tube.
• When installing the tire onto the wheel, observe the following points.
• When installing the tire, the arrow 1 on the side wall should point to the direction of wheel rotation.
• In case of a new tire, align the light point mark 2 on the tire side wall to the valve hole to balance the tire and wheel.
• Align the chalk mark put on the tire at the time of removal with the valve position.
• For installation procedure of tire onto the wheel, follow the instructions given by the tire changer manufacturer.
• Be careful not to catch the tire.
• Bounce the tire several times while rotating. This makes the tire bead expand outward to contact the wheel, thereby facilitating air inflation.
• Inflate the tire.
(
* Do not inflate the tire to more than 400 kPa (4.0 kgf/ cm 2 ). If inflated beyond this limit, the tire can burst and possibly cause injury. Do not stand directly over the tire while inflating.
* In the case of preset pressure air inflator, pay special care for the set pressure adjustment.
CHASSIS 5-51
5-52 CHASSIS
• In this condition, check the “rim line” cast on the tire side walls. The line must be equidistant from the wheel rim all around. If the distance between the rim line and wheel rim varies, this indicates that the bead is not properly seated. If this is the case, deflate the tire completely and unseat the bead for both sides. Coat the bead with lubricant and fit the tire again.
• When the bead has been fitted properly, adjust the pressure to specification.
• As necessary, adjust the tire balance.
(
* After mending a puncture of the tire, do not travel with that tire at a speed of more than 50 km/h at least for 24 hours after mending.
* Do not run with a repaired tire at a high speed.
$
Tire pressure
Solo riding and Dual riding:
Front: 125 kPa (1.25 kgf/cm 2 )
Rear: 125 kPa (1.25 kgf/cm 2 )
Rim line
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM 6-1
CONTENTS
SEMI-CONDUCTOR EQUIPPED PART ................................................6- 2
CONNECTING THE BATTERY ..............................................................6- 3
WIRING PROCEDURE ...........................................................................6- 3
USING THE MULTI CIRCUIT TESTER ..................................................6- 3
LOCATION OF ELECTRICAL COMPONENTS ............................................6- 4
TROUBLESHOOTING ...........................................................................6- 7
STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM ......6-11
TROUBLE SHOOTING ..........................................................................6-12
STARTER MOTOR REMOVAL AND DISASSEMBLY ..........................6-13
STARTER MOTOR INSPECTION ..........................................................6-13
STARTER MOTOR REASSEMBLY .......................................................6-14
STARTER RELAY INSPECTION ...........................................................6-15
SIDE-STAND/IGNITION INTERLOCK SYSTEM PARTS INSPECTION .....6-16
TROUBLESHOOTING ...........................................................................6-19
BRAKE LIGHT/TAILLIGHT ....................................................................6-24
TURN SIGNAL LIGHT ............................................................................6-25
TURN SIGNAL/SIDE-STAND RELAY ...................................................6-26
STARTER RELAY ..................................................................................6-26
THROTTLE POSITION SENSOR ..................................................................6-26
IGNITION SWITCH REMOVAL ..............................................................6-27
INITIAL CHARGING ...............................................................................6-29
RECHARGING OPERATION .................................................................6-31
6
6-2 ELECTRICAL SYSTEM
CAUTIONS IN SERVICING
CONNECTOR
• When connecting a connector, be sure to push it in until a click is felt.
• Inspect the connector for corrosion, contamination and breakage in its cover.
COUPLER
• With a lock type coupler, be sure to release the lock before disconnecting and push it in fully till the lock works when connecting.
• When disconnecting the coupler, be sure to hold the coupler body and do not pull the lead wires.
• Inspect each terminal on the coupler for being loose or bent.
• Inspect each terminal for corrosion and contamination.
CLAMP
• Clamp the wire harness at such positions as indicated in
“WIRE ROUTING”. (
!
7-11)
• Bend the clamp properly so that the wire harness is clamped securely.
• In clamping the wire harness, use care not to allow it to hang down.
• Do not use wire or any other substitute for the band type clamp.
FUSE
• When a fuse blows, always investigate the cause, correct it and then replace the fuse.
• Do not use a fuse of a different capacity.
• Do not use wire or any other substitute for the fuse.
SEMI-CONDUCTOR EQUIPPED PART
• Be careful not to drop the part with semi-conductor built in such as ECM.
• When inspecting this part, follow inspection instruction strictly.
Neglecting proper procedure may cause damage to this part.
BATTERY
• The MF battery used in this motorcycle does not require maintenance (e.g., electrolyte level inspection, distilled water replenishment).
• During normal charging, no hydrogen gas is produced. However, if the battery is overcharged, hydrogen gas may be produced. Therefore, be sure there are no fire or spark sources
(e.g., short circuit) nearby when charging the battery.
• Be sure to recharge the battery in a well-ventilated and open area.
• Note that the charging system for the MF battery is different from that of a conventional battery. Do not replace the MF battery with a conventional battery.
CONNECTING THE BATTERY
• When disconnecting terminals from the battery for disassembly or servicing, be sure to disconnect the battery lead wire, first.
• When connecting the battery lead wires, be sure to connect the + battery lead wire, first.
• If the terminal is corroded, remove the battery, pour warm water over it and clean it with a wire brush.
• After connecting the battery, apply a light coat of grease to the battery terminals.
• Install the cover over the + battery terminal.
WIRING PROCEDURE
• Properly route the wire harness according to the “WIRE
ROUTING” section. (
!
7-11)
USING THE MULTI CIRCUIT TESTER
• Properly use the multi circuit tester + and probes.
Improper use can cause damage to the motorcycle and tester.
• If the voltage and current values are not known, begin measuring in the highest range.
• When measuring the resistance, make sure that no voltage is applied. If voltage is applied, the tester will be damaged.
• After using the tester, be sure to turn the switch to the OFF position.
"
Before using the multi circuit tester, read its instruction manual.
ELECTRICAL SYSTEM 6-3
6-4 ELECTRICAL SYSTEM
LOCATION OF ELECTRICAL COMPONENTS
Battery
Regulator/rectifier
Side-stand switch
Neutral switch
Generator
Pick-up coil
Throttle position sensor
Starter relay
Fuse
Turn signal/side-stand relay
Ignitor
Ignition coil
Starter motor
Rear brake light switch
ELECTRICAL SYSTEM 6-5
6-6 ELECTRICAL SYSTEM
CHARGING SYSTEM
Generator
Regulator/rectifier
SCR SCR
SCR SCR SCR
IC
IG. switch
Load
ELECTRICAL SYSTEM 6-7
TROUBLESHOOTING
Battery runs down quickly.
Check accessories which use excessive amounts of electricity.
No accessories
Check the battery for current leaks. (
:
6-8)
No current leaks
Measure the charging voltage between the battery terminals.
( : 6-8)
Incorrect
Measure the continuity of the generator coil.
( : 6-9)
Continuity
Measure the generator no-load voltage. (
:
6-9)
Correct
Inspect the regulator/rectifier.
( : 6-10)
Correct
Inspect wirings.
Correct
Accessories are installed
Current leaks
Correct
No continuity
Incorrect
Incorrect
Incorrect
• Remove accessories.
• Short circuit of wire harness
• Faulty electrical equipment
• Faulty battery
• Abnormal driving condition
• Faulty generator coil or disconnected lead wires
• Faulty generator
• Faulty regulator/rectifier
• Short circuit of wire harness
• Poor contact of couplers
• Faulty battery
Others
Battery overcharge • Faulty regulator/rectifier
• Faulty battery
• Poor contact of generator lead wire coupler
6-8 ELECTRICAL SYSTEM
INSPECTION
BATTERY CURRENT LEAKAGE
• Remove the seat. (
!
5-3)
• Turn the ignition switch to the “OFF” position.
• Disconnect the battery lead wire.
Measure the current between the battery terminal and battery lead wire using the multi circuit tester. If the reading exceeds the specified value, leakage is evident.
#
09900-25008: Multi circuit tester set
$
Tester knob indication: Current (
%
, 20 mA)
&
Battery current (leak): Under 1 mA
"
* Because the current leak might be large, turn the tester to high range first to avoid tester damage.
* Do not turn the ignition switch to the “ON” position when measuring current.
When checking to find the excessive current leakage, remove the couplers and connectors, one by one, checking each part.
REGULATED VOLTAGE
• Remove the seat. (
!
5-3)
• Start the engine and keep it running at 5 000 r/min with dimmer switch turned “HI” position.
Measure the DC voltage between the
+
and
-
battery terminals using the multi circuit tester. If the voltage is not within the specified value, inspect the generator and regulator/rectifier.
(
!
6-9, 6-10)
NOTE:
When making this test, be sure that the battery is in fullycharged condition.
#
09900-25008: Multi circuit tester set
'
Tester knob indication: Voltage (
%
)
&
Charging output (Regulated voltage):
14.0 – 15.5 V at 5 000 r/min
Battery
(DCV)
Tester
ELECTRICAL SYSTEM 6-9
GENERATOR COIL RESISTANCE
• Remove the seat. (
!
5-3)
• Remove the fuel tank. (
!
4-2)
• Disconnect the generator coupler.
Measure the resistance between three lead wires.
If the resistance is not specified value, replace the stator with a new one. Also, check that the generator core is insulated.
#
09900-25008: Multi circuit tester set
(
Tester knob indication: Resistance (
Ω
)
&
Generator coil resistance: 0.4 – 0.8
Ω
(Black – Black)
∞ Ω
(Black – Ground)
NOTE:
When making above test, it is not necessary to remove the generator.
GENERATOR NO-LOAD PERFORMANCE
• Remove the seat. (
!
5-3)
• Remove the fuel tank. (
!
4-2)
• Disconnect the generator coupler.
• Start the engine and keep it running at 5 000 r/min.
Using the multi circuit tester, measure the voltage between three lead wires.
If the tester reads under the specified value, replace the generator with a new one.
#
09900-25008: Multi circuit tester set
'
Tester knob indication: Voltage (
∼∼∼∼
)
&
Generator no-load performance:
More than 60 V at 5 000 r/min (When engine is cold)
B
B
B
B
B
B
6-10 ELECTRICAL SYSTEM
REGULATOR/RECTIFIER
• Remove the engine sprocket cover. (
!
3-5)
• Remove the regulator/rectifier.
• Disconnect the regulator/rectifier coupler.
Measure the voltage between the terminals using the multi circuit tester as indicated in the table below. If the voltage is not within the specified value, replace the regulator/rectifier with a new one.
#
09900-25008: Multi circuit tester set
)
Tester knob indication: Diode test (
*
)
Unit: V
B
B
2
B
3
R
1
+ Probe of tester to:
B
✽
✽
1
B
✽
✽
2
B
3
✽
✽
0.4 – 0.7 0.4 – 0.7 0.4 – 0.7
✽ ✽ ✽
R
✽
✽
✽
B/W
✽
✽
More than 1.4 V (tester’s battery voltage)
Above are approximate values for reference purpose.
B/W
0.4 – 0.7
0.4 – 0.7
0.4 – 0.7
0.5 – 1.2
NOTE:
If the tester reads under 1.4 V when the tester probes are not connected, replace the battery of multi circuit tester.
B
1
B
2
B 3
ELECTRICAL SYSTEM 6-11
STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK
SYSTEM
Neutral indicator
Engine stop switch
OFF
RUN
Starter button
PUSH
IG. switch
ON
OFF
LOCK
Side-stand switch
PUSH
FREE
Turn signal/ side-stand relay
B L
OFF
ON
Neutral switch
FREE
Clutch lever position switch
Starter motor
Starter relay
1 : Fuse 20 A
Battery
6-12 ELECTRICAL SYSTEM
TROUBLE SHOOTING
Starter motor will not run.
The transmission is in neutral. Grasp the clutch lever, turn on the ignition switch with the engine stop switch in the “RUN” position and listen for a click from the starter relay when the starter button is pushed.
Clicks
Check if the starter motor runs when its terminal is connected to the battery
+
terminal. (Do not use thin “wire” because a large amount of current flows.)
Runs Does not run
No click
Measure the starter relay voltage at the starter relay connectors (between Y/G
+ and Y/B pushed.
) when the starter button is
Voltage
No voltage
• Faulty starter motor
• Faulty starter relay
• Loose or disconnected starter motor lead wire
• Faulty ignition switch
• Faulty engine stop switch
• Faulty clutch lever position switch
• Faulty neutral switch
• Faulty turn signal/ side-stand relay
• Faulty starter button
• Poor contact of connector
• Open circuit in wire harness
Check the starter relay.
(
:
6-15)
Incorrect • Faulty starter relay
Correct
• Poor contact of the starter relay
The starter motor runs when the transmission is in neutral with the side-stand up or down, but does not run when the transmission is in any position other than neutral with the side-stand down.
Check the side-stand switch.
(
:
6-16)
Correct
Incorrect • Faulty side-stand switch
• Open circuit in wire harness
• Poor contact of connector
Others
Engine does not turn though the starter motor runs.
• Faulty starter clutch
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 6-13
STARTER MOTOR INSPECTION
CARBON BRUSH
Inspect the brushes for abnormal wear, cracks, or smoothness in the brush holder.
If any damages are found, replace the brush assembly with a new one.
COMMUTATOR
Inspect the commutator for discoloration, abnormal wear or undercut A .
If abnormal wear is found, replace the armature with a new one.
If the commutator surface is discolored, polish it with #400 sand paper and wipe it using a clean dry cloth.
If there is no undercut, scrape out the insulator 1 with a saw blade.
O-ring (2pcs)
O-ring
Housing end
O-ring (2pcs)
Starter motor case
Armature
Housing end
6-14 ELECTRICAL SYSTEM
ARMATURE COIL INSPECTION
Check for continuity between each segment and the armature shaft using the multi circuit tester.
If there is no continuity between the segments or there is continuity between the segments and shaft, replace the armature with a new one.
#
09900-25008: Multi circuit tester set
+
Tester knob indication: Continuity test (
,
)
OIL SEAL INSPECTION
Check the oil seal lip for damage or leakage.
If any damage is found, replace the housing end.
STARTER MOTOR REASSEMBLY
Reassemble the starter motor in the reverse order of disassembly. Pay attention to the following points:
• Apply SUSUKI SUPER GREASE to the lip of the oil seal.
-
99000-25010: SUZUKI SUPER GREASE “A”
• Apply a small quantity of SUZUKI MOLY PASTE to the armature shaft.
.
99000-25140: SUZUKI MOLY PASTE
• Align the match mark 1 on the starter motor case with the match mark 2 on the housing end.
• Apply a small quantity of THREAD LOCK to the starter motor housing bolts.
/
99000-32050: THREAD LOCK “1342”
• Apply SUZUKI SUPER GREASE to the O-ring.
-
99000-25010: SUZUKI SUPER GREASE “A”
STARTER RELAY INSPECTION
• Remove the right frame cover. (
!
5-3)
• Disconnect the battery lead wire from the battery.
• Remove the starter relay cover 1 .
• Disconnect the starter relay coupler 2 .
• Disconnect the starter motor lead wire 3 and battery lead wire 4 .
• Remove the starter relay 5 .
Apply 12 V to A and B terminals and check for continuity between the positive and negative terminals using the multi circuit tester. If the starter relay clicks and continuity is found, the relay is OK.
#
09900-25008: Multi circuit tester set
+
Tester knob indication: Continuity test (
,
)
"
Do not apply a battery voltage to the starter relay for more than five seconds, since the relay coil may overheat and damaged.
Measure the relay coil resistance between the terminals using the multi circuit tester. If the resistance is not within the specified value, replace the starter relay with a new one.
#
09900-25008: Multi circuit tester set
(
Tester knob indication: Resistance (
Ω
)
&
Starter relay resistance: 3 – 6 Ω
ELECTRICAL SYSTEM 6-15
6-16 ELECTRICAL SYSTEM
SIDE-STAND/IGNITION INTERLOCK
SYSTEM PARTS INSPECTION
Check the interlock system for proper operation. If the interlock system does not operate properly, check each component for damage or abnormalities. If any abnormality is found, replace the component with a new one.
SIDE-STAND SWITCH INSPECTION
• Remove the seat. (
!
5-3)
• Disconnect the side-stand switch coupler and measure the voltage between Green and Black/White lead wires.
#
09900-25008: Multi circuit tester set
)
Tester knob indication: Diode test (
*
)
Green
(
+
Probe)
Black/White
(
-
Probe)
ON
(Side-stand up)
OFF
(Side-stand down)
0.4 – 0.6 V
More than 1.4 V
(Tester’s battery voltage)
NOTE:
If the tester reads under 1.4 V when the tester probes are not connected, replace its battery.
NEUTRAL SWITCH INSPECTION
• Remove the seat. (
!
5-3)
• Remove the fuel tank. (
!
4-2)
• Disconnect the neutral switch coupler and check the continuity between Blue and Ground with the transmission in “NEU-
TRAL”.
Blue Ground
ON (Neutral)
OFF (Expect neutral)
"
When disconnecting and connecting the neutral switch coupler, make sure to turn “OFF” the ignition switch, or electronic parts may get damaged.
#
09900-25008: Multi circuit tester set
+
Tester knob indication: Continuity test (
,
)
TURN SIGNAL/SIDE-STAND RELAY
The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode.
• Remove the right frame cover. (
!
5-3)
• Remove the turn signal/side-stand relay.
SIDE-STAND RELAY INSPECTION
First check the insulation between D and E terminals with the tester. Then apply 12 V to terminals D and C ( + to D and to
C ) and check the continuity between D and E . If there is no continuity, replace the turn signal/side-stand relay with a new one.
#
09900-25008: Multi circuit tester set
+
Tester knob indication: Continuity test (
,
)
ELECTRICAL SYSTEM 6-17
DIODE INSPECTION
Measure the voltage between the terminals using the multi circuit tester. Refer to the following table.
Unit: V
More than 1.4 V
(Tester’s battery voltage)
0.4 – 0.6
#
09900-25008: Multi circuit tester set
)
Tester knob indication: Diode test (
*
)
NOTE:
If the multi circuit tester reads under 1.4 V when the tester probes are not connected, replace its battery.
6-18 ELECTRICAL SYSTEM
IGNITION SYSTEM
Fuse
Battery
IG. switch
Fuse
Side-stand relay
Engine stop switch
Pick-up coil
TPS
6
3 8
1
2
7
Ignitor
5
4
IG. coil
Neutral switch
NOTE:
The ignition cut-off circuit is incorporated in this ignitor to prevent over-running of engine. If engine rpm reaches 10 000 r/min, this circuit cuts off the ignition primary current for the spark plug.
"
Under no load, the engine can run over 10 000 r/min though the ignition cut-off circuit is effective, which may possibly cause engine damage. Do not run the engine without load over
10 000 r/min at anytime.
ELECTRICAL SYSTEM 6-19
TROUBLESHOOTING
No spark or poor spark
Check the ignition system couplers for poor connections.
Correct
Measure the battery voltage between input lead wires (O/W and B/W) at the ignitor with the ignition switch in the
“ON” position.
Correct
Measure the ignition coil primary peak voltage. (
:
6-20)
NOTE: The ignition coil peak voltage inspection method is applicable only with the multi circuit tester and the peak volt adaptor.
Incorrect
* Make sure the transmission is in neutral and the engine stop switch is in the “RUN” position. Grasp the clutch lever. Make sure the fuse is not blown and the battery is fully-charged before diagnosing.
Loose • Improper coupler connection
Incorrect
Correct
• 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.
(
:
2-7)
Correct Incorrect
• Faulty spark plug
• Improper spark plug connection
• Faulty ignition coil
Inspect the ignition coil. ( : 6-21)
Correct
Measure the pick-up coil peak voltage and resistance. (
:
6-21, 22)
NOTE: The pick-up coil peak voltage inspection is applicable only with the multi circuit tester and peak volt adaptor.
Correct
Incorrect
Incorrect • Faulty generator
• Faulty ignitor
• Faulty wire harness
• Improper ignition coupler connection
6-20 ELECTRICAL SYSTEM
INSPECTION
IGNITION COIL PRIMARY PEAK VOLTAGE
• Disconnect the spark plug cap.
• Connect a new spark plug to the spark plug cap and ground it to the cylinder head.
NOTE:
Make sure that all couplers and spark plug are connected properly and the battery is used in fully-charged condition.
Measure the ignition coil primary peak voltage using the multi circuit tester in the following procedure:
• Connect the multi circuit tester with the peak voltage adaptor as follows.
+
Probe: Black terminal
-
Probe: Ground
NOTE:
Do not disconnect the ignition coil primary lead wire.
#
09900-25008: Multi circuit tester set
"
Before using the multi circuit tester and peak volt adaptor, be sure to refer to the appropriate instruction manual.
• Shift the transmission into the neutral, and then turn the ignition switch to the “ON” position.
• Squeeze the clutch lever.
• Press the starter button and allow the engine to crank for a few seconds, and then measure the ignition coil primary peak voltage.
• Repeat the above procedure a few times and measure the highest ignition coil primary peak voltage.
'
Tester knob indication: Voltage (
%
)
&
Ignition coil primary peak voltage: More than 200 V
0
While testing, do not touch the tester probes and spark plugs to prevent receiving an electric shock.
If the peak voltage is lower than the specified values, inspect the ignition coil. (
!
6-21)
Peak volt adaptor
Ignitor
IG. coil
To engine stop swicth
DCV (
-
)
Set
IGNITION COIL RESISTANCE
• Disconnect the ignition coil lead wires and plug cap.
Measure the ignition coil resistance in both the primary and secondary windings. If the resistance is not within the standard range, replace the ignition coil with a new one.
#
09900-25008: Multi circuit tester set
(
Tester knob indication: Resistance (
Ω
)
&
Ignition coil resistance
Primary : 1.6 – 2.7
Ω
(
+
terminal –
-
terminal)
Secondary: 18 – 26 k
Ω
(Plug cap – + terminal)
PICK-UP COIL PEAK VOLTAGE
• Remove the right frame cover. (
!
5-3)
• Disconnect the wire harness coupler 1 at the ignitor.
NOTE:
Make sure that all of the couplers are connected properly and the battery is used in fully-charged condition.
Measure the pick-up coil peak voltage in the following procedures:
• Connect the multi circuit tester with peak volt adaptor as follows.
+ Probe: Blue lead wire
-
Probe: Black/White lead wire
#
09900-25008: Multi circuit tester set
"
Before using the multi circuit tester and peak volt adaptor, be sure to refer to the appropriate instruction manual.
ELECTRICAL SYSTEM 6-21
6-22 ELECTRICAL SYSTEM
• Shift the transmission into the neutral, and then turn the ignition switch to the “ON” position.
• Squeeze 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 peak voltage.
'
Tester knob indication: Voltage (
%
)
&
Pick-up coil peak voltage: More than 2.0 V
If the peak voltage is lower than the specified values, check the peak voltage at the pick-up coil lead wire coupler.
Pick-up coil coupler
B/W
Ignitor coupler
Bl
Pick-up coil
Peak volt adaptor
• Remove the seat. (
!
5-3)
• Remove the fuel tank. (
!
4-2)
• Disconnect the pick-up coil lead wire coupler and connect the multi circuit tester with the peak volt adaptor.
+ Probe: Blue lead wire
Probe: Green lead wire
Measure the pick-up coil peak voltage at the pick-up coil lead wire coupler in the same manner as on the ignitor coupler.
'
Tester knob indication: Voltage (
%
)
&
Pick-up coil peak voltage: More than 2.0 V
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 pick-up coil must be replaced and re-checked.
G
Pick-up coil
Bl
Pick-up coil coupler
Peak volt adaptor
PICK-UP COIL RESISTANCE
Measure the resistance between the lead wires and ground. If the resistance is not as specified, the pick-up coil must be replaced.
#
09900-25008: Multi circuit tester set
(
Tester knob indication: Resistance ( Ω )
&
Pick-up coil resistance: 172 – 288 Ω (Green – Blue)
∞ Ω (Green – Ground)
Pick-up coil couper
Pick-up coil
SPEEDOMETER
• Disassemble the speedometer as follows.
ELECTRICAL SYSTEM 6-23
6-24 ELECTRICAL SYSTEM
LAMPS
HEADLIGHT
"
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.
BRAKE LIGHT/TAILLIGHT
"
Do not overtighten the lens fitting screws.
TURN SIGNAL LIGHT
ELECTRICAL SYSTEM 6-25
"
Do not overtighten the lens fitting screws.
HEADLIGHT BEAM ADJUSTMENT
• Adjust the headlight beam, both vertical and horizontal.
A : Vertical adjuster
B : Horizontal adjuster
6-26 ELECTRICAL SYSTEM
RELAYS
TURN SIGNAL/SIDE-STAND RELAY
The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode.
TURN SIGNAL INSPECTION
Before removing the turn signal/side-stand relay, check the operation of the turn signal light.
If the turn signal light does not illuminate, inspect the bulb, turn signal switch and circuit connection.
If the bulb, turn signal switch and circuit connection are OK, the turn signal relay may be faulty; therefore, replace the turn signal/ side-stand relay with a new one.
NOTE:
* Make sure that the battery is fully charged.
* Refer to the page 6-17 for the side-stand relay and diode inspection.
STARTER RELAY
!
6-15
THROTTLE POSITION SENSOR
!
4-11
SWITCHES
IGNITION SWITCH REMOVAL
• Remove the seat. (
!
5-3)
• Remove the fuel tank. (
!
4-2)
• Disconnect the ignition switch coupler.
• Remove the ignition switch mounting bolts using the special tools.
#
09930-11920: Torx bit JT40H
09930-11940: Bit holder
"
When reusing the ignition switch bolt, clean its thread and apply the THREAD LOCK SUPER.
1
99000-32110: THREAD LOCK SUPER “1322”
ELECTRICAL SYSTEM 6-27
6-28 ELECTRICAL SYSTEM
Inspect each switch for continuity with a tester. If any abnormality is found, replace the respective switch assemblies with new ones.
IGNITION SWITCH
Color
Position
ON
OFF
LOCK
P
R O O/Y B/W Gr
DIMMER SWITCH
Color
Position
HI (
µ )
LO ( ¶ )
W
TURN SIGNAL SWITCH
Color
Position
Lg
L
PUSH
R
Y
Lbl
ENGINE STOP SWICH
Color
Position
OFF ( À )
RUN ( ¾ )
O/B
STARTER BUTTON
Color
Position
O/W
O/W
Y/G
Y/W
B
Br
FRONT BRAKE SWITCH
Color
Position
OFF
ON
B/R B/Bl
REAR BRAKE SWITCH
Color
Position
OFF
O
ON
W/B
CLUTCH LEVER POSITION SWITCH
Color
Position
B/W B/Y
OFF
ON
WIRE COLOR
B : Black
Br : Brown
Gr : Gray
Lbl : Light blue
Lg : Light green
O : Orange
R : Red
Y : Yellow
W : White
B/Bl : Black with Blue tracer
B/R : Black with Red tracer
B/W : Black with White tracer
B/Y : Black with Yellow tracer
O/B : Orange with Black tracer
O/W : Orange with White tracer
O/Y : Orange with Yellow tracer
W/B : White with Black tracer
Y/G : Yellow with Green tracer
Y/W : Yellow with White tracer
PUSH
HORN BUTTON
Color
Position
B/Bl B/W
PUSH
HAZARD
Color
Position
ON
OFF
Lg Lbl B
BATTERY
SPECIFICATIONS
Type designation
Capacity
YTX7L-BS
12 V, 21.6 kC (6 Ah)/10 HR
INITIAL CHARGING
FILLING ELECTROLYTE
• Remove the aluminum tape 1 sealing the battery electrolyte filler holes.
• Remove the caps 2 .
NOTE:
* After filling the electrolyte completely, use the removed caps
2 as the sealed caps of battery filler holes.
* Do not remove or pierce the sealed areas 3 of the electrolyte container.
• Insert the nozzles of the electrolyte container into the battery’s electrolyte filler holes, holding the container firmly so that it does not fall. Take precaution not to allow any of the fluid to spill.
• Make sure air bubbles are coming up each electrolyte container, and leave in this position for about more than 20 minutes.
ELECTRICAL SYSTEM 6-29
6-30 ELECTRICAL SYSTEM
NOTE:
If no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times.
Never remove the container from the battery.
• After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the battery. Wait for about more than 20 minutes.
• Insert the caps into the filler holes, pressing in firmly so that the top of the caps do not protrude above the upper surface of the battery’s top cover.
"
* Never use anything except the specified battery.
* Once install the caps to the battery; do not remove the caps.
* Do not tap the caps with a hammer when installing them.
CORRECT INCORRECT
• For initial charging, use the charger specially designed for MF battery.
"
* For charging the battery, make sure to use the charger specially designed for MF battery. Otherwise, the battery may be overcharged resulting in shortened service life.
* Do not remove the cap during charging.
* Position the battery with the cap facing upward during charging.
ELECTRICAL SYSTEM 6-31
SERVICING
Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, then this can be cleaned away with sandpaper.
RECHARGING OPERATION
• Using the multi circuit tester, check the battery voltage. If the voltage reading is less than the 12.0 V (DC), recharge the battery with a battery charger.
"
* When recharging the battery, remove the battery from the motorcycle.
* Do not remove the caps on the battery top while recharging.
Recharging time: 0.7 A for 5 to 10 hours or 3 A for one hour
"
Be careful not to permit the charging current to exceed 3 A at any time.
• After recharging, wait for more than 30 minutes and check the battery voltage with a multi circuit tester.
• If the battery voltage is less than the 12.5 V, recharge the battery again.
• If battery voltage is still less than 12.5 V, after recharging, replace the battery with a new one.
• When 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.
(at 0 ˚C – 40 ˚C)
SERVICING INFORMATION
SERVICING INFORMATION 7-1
CONTENTS
ENGINE ELECTRICAL PARTS WIRE ROUTING .........................................7-12
FRONT BRAKE HOSE ROUTING ................................................................7-14
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING .........................................7-15
SPEEDOMETER CABLE ROUTING .............................................................7-16
SIDE-STAND INSTALLATION ......................................................................7-16
FUEL TANK INSTALLATION ........................................................................7-17
REAR BRAKE PEDAL INSTALLTAION .......................................................7-17
DRIVE CHAIN GUIDE ROLLER INSTALLATION ........................................7-18
HANDLEBAR BALANCER INSTALLATION ................................................7-18
EXHAUST PIPE AND MUFFLER INSTALLATION .......................................7-19
CARBURETOR AND AIR CLEANER INSTALLATION ................................7-20
TIGHTENING TORQUE CHART ............................................................7-26
7
7-2 SERVICING INFORMATION
TROUBLESHOOTING
ENGINE
Complaint
Engine will not start or is hard to start.
Engine stalls easily.
Symptom and possible causes
Compression too low
1. Worn cylinder
2. Worn piston ring
3. Worn valve guide or improper valve seating
4. Loose spark plug
5. Broken, cracked, or damaged piston
6. Mistimed valves
7. 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 generator
8. Defective ignitor unit
9. Defective pick-up coil
No fuel reaching the carburetor
1. Clogged fuel tank vent hose
2. Clogged or defective fuel valve
3. Defective carburetor needle valve
4. Clogged fuel hose
5. Clogged fuel filter
1. Fouled spark plug
2. Defective generator
3. Defective ignitor unit
4. Clogged or defective fuel valve
5. Clogged carburetor jet
6. Valve clearance out of adjustment
Remedy
Replace.
Replace.
Repair or replace.
Tighten.
Replace.
Adjust.
Adjust.
Replace.
Replace.
Clean or replace.
Clean and dry or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Clean or replace.
Clean or replace.
Replace.
Clean or replace.
Clean or replace.
Clean or replace.
Replace.
Replace.
Clean or replace.
Clean.
Adjust.
SERVICING INFORMATION 7-3
Complaint
Engine is noisy.
Symptom and possible causes
Excessive valve chatter
1. Excessive valve clearance
2. Weak or broken valve spring
3. Worn camshaft
4. Worn or burnt camshaft journal
Noise seems to come from the piston
1. Worn piston
2. Worn cylinder
3. Carbon 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
1. Stretched cam chain
2. Worn cam chain sprocket
3. Improperly working cam chain tensioner
Noise seems to come from the clutch
1. Worn crankshaft spline
2. Worn clutch hub spline
3. Worn clutch plate teeth
4. Distorted clutch plate
5. Weak clutch damper
6. Weak clutch spring
Noise seems to come from the crankshaft
1. Ratting bearing
2. Worn or burnt crank pin bearing
3. Worn or burnt journal bearing
Clutch slips.
Clutch drags.
Transmission will not shift or shift back.
Transmission jumps out of gear.
Noise seems to come from 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. Broken gearshift shaft return spring
3.
Distorted gearshift fork
4. Rubbing or stuck gearshift shaft
5. Worn gearshift pawl
1. Worn gear
2. Worn or distorted gearshift fork
3. Weakened gearshift stopper spring
4. Worn gearshift pawl
Remedy
Adjust.
Replace.
Replace.
Replace.
Replace.
Replace.
Clean.
Replace.
Replace.
Replace cam chain and sprockets.
Replace cam chain and sprockets.
Repair or replace.
Replace countershaft.
Replace clutch hub.
Replace clutch plate.
Replace.
Replace primary driven gear.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace countershaft.
Replace driveshaft.
Replace.
Replace.
Adjust.
Replace.
Replace.
Replace.
Adjust.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Repair or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
7-4 SERVICING INFORMATION
Complaint
Engine idles poorly.
Engine runs poorly in high-speed range.
Exhaust smoke is dirty or thick.
Engine lacks power.
Symptom and possible causes
1. Valve clearance out of adjustment
2. Improper valve seating
3. Worn valve guide
4. Worn camshaft
5. Excessive spark plug gap
6. Defective ignition coil
7. Defective generator
8. Defective ignitor unit
9. Defective pick-up coil
10. Incorrect float chamber fuel level
11. Clogged carburetor jet
Remedy
Adjust.
Repair or replace.
Replace.
Replace.
Adjust or replace.
Replace.
Replace.
Replace.
Replace.
Adjust float height.
Clean.
1. Weak valve spring
2. Worn camshaft
3. Insufficient spark plug gap
4. Mistimed valves
5. Ignition not advanced sufficiently due to poorly working timing advance circuit
6. Defective ignition coil
7. Defective generator
8. Defective ignitor unit
9. Low float chamber fuel level
10. Dirty air cleaner element
11. Clogged fuel hose, resulting in inadequate fuel supply to carburetor
1. Excessive amount of engine oil
2. Worn cylinder
3. Worn piston ring
4. Worn valve guide
5. Scored or scuffed cylinder wall
6. Worn valve stem
7. Defective valve stem oil seal
8. Worn oil ring side rail
1. Insufficient valve clearance
2. Weak valve spring
3. Mistimed valves
4. Worn cylinder
5. Worn piston ring
6. Improper valve seating
7. Fouled spark plug
8. Incorrect spark plug
9. Clogged carburetor jet
10. Incorrect float chamber fuel level
11. Dirty air cleaner element
12. Air leakage from intake pipe
13. Excessive amount of engine oil
Replace.
Replace.
Regap or replace.
Adjust.
Replace CDI unit.
Replace.
Replace.
Replace.
Adjust float height.
Clean or replace.
Clean and prime.
Check level and drain.
Replace.
Replace.
Replace.
Replace.
Replace valve.
Replace.
Replace oil ring.
Adjust.
Replace.
Adjust.
Replace.
Replace.
Repair or replace.
Clean or replace.
Replace.
Clean.
Adjust float height.
Clean or replace.
Tighten or replace.
Check level and drain.
SERVICING INFORMATION 7-5
Complaint
Engine overheats.
Symptom and possible causes
1. Carbon buildup on piston crown
2. Insufficient amount of engine oil
3. Defective oil pump
4. Clogged oil circuit
5. Float chamber fuel level too low
6. Air leakage from intake pipe
7. Incorrect engine oil
Remedy
Clean.
Check level and add.
Replace.
Clean.
Adjust float height.
Tighten or replace.
Change.
CARBURETOR
Complaint
Starting difficulty.
Idling or low-speed trouble
Medium or high- speed trouble
Overflow and fuel level fluctuations
Symptom and possible causes
1. Clogged starter jet
2. Clogged starter jet passage
3. Air leaking from joint between starter body and carburetor
4. Air leaking from carburetor joint or vacuum hose joint
Remedy
Clean.
Clean.
Tighten, adjust, or replace gasket.
Tighten or replace defective part.
Adjust.
5. Improperly working starter (enricher) plunger
1. Clogged or loose pilot jet
2. Clogged or loose pilot air jet
3. Air leaking from carburetor joint
4. Clogged pilot outlet port
5. Clogged bypass port
6. Starter (enricher) plunger not fully closed
1. Clogged main jet
2. Clogged main air jet
3. Clogged needle jet
4. Improperly working throttle valve
5. Clogged fuel filter
1. Worn or damaged needle valve
2. Broken needle valve spring
3. Improperly working float
4. Foreign matter on the needle valve
5. Incorrect float chamber fuel level
Clean or tighten.
Clean or tighten.
Tighten or replace defective part.
Clean.
Clean.
Adjust.
Clean.
Clean.
Clean.
Adjust.
Clean or replace.
Replace.
Replace.
Adjust or replace.
Clean or replace with needle valve seat.
Adjust float height.
7-6 SERVICING INFORMATION
CHASSIS
Complaint Symptom and possible causes
Steering is heavy.
Handlebar wobbles.
1. Overtightened steering stem nut
2. Broken bearing in steering stem
3. Distorted steering stem
4. Low tire pressure
1. Loss of balance between right and left front forks
2. Distorted front fork
3. Distorted front axle
4. Twisted tire
Front wheel wobbles.
1. Distorted wheel rim
2. Worn front wheel bearing
3. Defective or incorrect tire
4. Loose front axle nut
5. Incorrect fork oil level
Front suspension too soft
Front suspension too stiff
1. Weak spring
2. Insufficient fork oil
3. Improper suspension setting
1. Excessively viscous fork oil
2. Excessive fork oil
3. Improper suspension setting
Front suspension too noisy
1. Insufficient fork oil
2. Loose front suspension fastener
Rear wheel wobbles.
1. Distorted wheel rim
2. Worn rear wheel bushing
3. Defective or incorrect tire
4. Worn swingarm bushing
5. Loose rear axle nut
6. Loose rear suspension fastener
Rear suspension too soft
Rear suspension too stiff
Rear suspension too noisy
1. Weak rear shock absorber spring
2. Rear shock absorber leaks oil
3. Improper suspension setting
1. Improper suspension setting
2. Bent rear shock absorber shaft
3. Worn swingarm bushing and rear suspension related bushing
Replace.
Replace.
Adjust.
Adjust.
Replace.
Replace.
1. Loose rear suspension fastener
2. Worn swingarm bushing and rear suspension related bushing
Tighten.
Replace.
Remedy
Adjust.
Replace.
Replace.
Regulate.
Adjust or replace.
Repair or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Tighten.
Adjust.
Replace.
Check level and add.
Adjust.
Replace.
Check level and drain.
Adjust.
Check level and add.
Tighten.
Replace.
Replace.
Replace.
Replace.
Tighten.
Tighten.
SERVICING INFORMATION 7-7
BRAKES
Complaint
Brake power insufficient
(FRONT)
Brake power insufficient
(REAR)
Brake squeaks.
(FRONT)
Brake squeaks.
(REAR)
Brake pedal stroke excessive
Brake lever stroke excessives
Brake fluid leaks.
Brake drags.
Symptom and possible causes
1. Leakage of brake fluid
2. Worn brake pad
3. Oil on brake pad surface
4. Worn brake disc
5. Air in hydraulic system
1. Worn brake shoe
2. Oil in brake shoe surfaces
3. Excessively worn brake drum
4. Excessive brake pedal play
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. Loose front or rear axle nut
1. Damaged wheel bearing
2. Brake shoe surface glazed
3. Loose rear axle nut
4. Worn brake shoe
1. Worn brake camshaft
2. Excessively worn brake shoes and/or brake drum
1. Air in hydraulic system
2. Insufficient brake fluid
3. Improper quality of brake fluid
1. Loose connection joint
2. Cracked hose
3. Worn piston seal
4. Worn secondary cup
1. Rusty part
2. Insufficient brake lever or brake pedal pivot lubrication
Remedy
Repair or replace.
Replace.
Clean brake disc and brake pads.
Replace.
Bleed.
Replace.
Clean.
Replace.
Adjust.
Clean surface with sandpaper.
Readjust brake pad position or replace.
Replace.
Replace.
Change brake fluid.
Disassemble and clean master cylinder.
Tighten.
Replace.
Clean surface with sandpaper.
Tighten to the specified torque.
Replace.
Replace.
Replace.
Bleed.
Replenish fluid to specified level and bleed air.
Replace with correct fluid.
Tighten.
Replace.
Replace.
Replace.
Clean and lubricate.
Lubricate.
7-8 SERVICING INFORMATION
ELECTRICAL
Complaint
No sparking or poor sparking
Spark plug is wet or quickly becomes fouled with carbon.
Spark plug quickly becomes fouled with oil or carbon.
Spark plug electrodes overheat or burn.
Generator does not charge.
Generator does charge, but charging rate is below the specification.
Generator overcharges.
Unstable charging
Starter button is not effective.
Symptom and possible causes
1. Defective ignition coil
2. Defective spark plug
3. Defective generator
4. Defective ignitor unit
1. Excessively rich air/fuel mixture
2. Excessively high idling speed
3. Incorrect gasoline
4. Dirty air cleaner element
5. Incorrect spark plug (cold type)
Remedy
Replace.
Replace.
Replace.
Replace.
Adjust carburetor.
Adjust carburetor.
Change.
Clean or replace.
Change to standard spark plug.
Replace.
Replace.
Replace.
Replace.
Replace.
1. Worn piston ring
2. Worn piston
3. Worn cylinder
4. Excessive valve-stem-to-valve-guide clearance
5. Worn valve stem oil seal
1. Incorrect spark plug (hot type)
2. Overheated engine
3. Loose spark plug
4. Excessively lean air/fuel mixture
1. Open- or short-circuited lead wires, or loose lead connections
2. Short-circuited, grounded or open generator coils
3. Short-circuited or panctured regulator/rectifiers
Change to cold type spark plug.
Turn-up.
Tighten.
Adjust carburetor.
Repair or replace or retighten.
Replace.
Replace.
Repair or retighten.
1. Lead wires tend to get short- or open-circuited or loosely connected at terminals
2. Grounded or open-circuited stator coils or generator
3. Defective regulator/rectifier
4. Defective cell plates in the battery
Replace.
Replace.
Replace the battery.
1. Internal short-circuit in the battery
2. Damaged or defective resistor element in the regulator/ rectifier
3. Poorly grounded regulator/rectifier
Replace the battery.
Replace.
Clean and tighten ground connection.
Repair or replace.
1. Lead wire insulation frayed due to vibration, resulting in intermittent short-circuiting
2. Internally short-circuited generator
3. Defective regulator/rectifier
Replace.
Replace.
1. Run down battery
2. Defective switch contacts
3. Brushes not seating properly on starter motor commutator
4. Defective starter relay/starter interlock switch.
5. Defective main fuse
Repair or replace.
Replace.
Repair or replace.
Replace.
Replace.
SERVICING INFORMATION 7-9
BATTERY
Complaint
“Sulfation”, acidic white powdery substance or spots on surfaces of cell plates
Battery runs down quickly.
Battery “sulfation”
Symptom and possible causes
1. Cracked battery case
2. Battery has been left in a run-down condition for a long time.
Remedy
Replace the battery.
Replace the battery.
1. Trouble in charging system
2. Cell plates have lost much of their active material as a result of overcharging.
3. Internal short-circuit in the battery
4. Too low battery voltage
5. Too old battery
1. Incorrect charging rate
(When not in use battery should be checked at least once a month to avoid sulfation.)
2. The battery was left unused in a cold climate for too long
Check the generator, regulator/ rectifier and circuit connections and make necessary adjustments to obtain specified charging operation.
Replace the battery, and correct the charging system.
Replace the battery.
Recharge the battery fully.
Replace the battery.
Replace the battery.
Replace the battery if badly sulfated.
7-10 SERVICING INFORMATION
WIRING DIAGRAM
W/B W/B W/B
O O
B/W B/W B/W
Br Br Br
Gr Gr Gr
O/Y O/Y O/Y
O O
R R
G G
B/W B/W B/W
O/Bl O/Bl O/Bl
O/R O/R O/R
O/W O/W O/W
O/B O/B O/B
B/Bl B/Bl B/Bl
B/R B/R B/R
Y/G Y/G Y/G
O/G O/G O/G
Y Y
B/W B/W B/W
Lg Lg Lg
B B
Bl/B Lg/B Lg/B
B/W B/W B/W
Gr Gr Gr O O
B/W
Y Y
B/W B/W B/W
Lg Lg Lg
O O
B B
Bl/B Lg/B Lg/B
B/W B/W
W/B W/B W/B
O/B O/B O/B
O O
B/O B/O B/O
Y/G Y/G Y/G
B B
B/O B/O B/O
Bl Bl Bl
Y Y
B/W B/W
Bl/B Bl/B
B/W
Bl/B
O/Y O/Y O/Y
B B
B/O O/G O/G
G/Bl G/Bl G/Bl
Y Y
Bl/B
B/W
Bl/B Bl/B
B/W B/W
W/B W/B W/B
O O
B B
B B
R R
B B
B/W B/W B/W
G G
B/W B/W B/W
Br Br Br
O O
B/W
O/Y O/Y O/Y
O O
R R
B/W B/W
B/W B/W B/W B/W B/W B/W
Y/G Y/G Y/G
R R
Y/B Y/B Y/B
B/W B/W B/W
B B
Bl/B Bl/B Bl/B
Bl Bl Bl
O O
G G
O/B O/B O/B
Lbl Lb Lbl
Br Br Br
G/Bl G/Bl G/Bl
Bl Bl Bl
B/W B/W B/W
B B
B B
B B
Bl Bl Bl
G/Bl G/Bl G/Bl
Bl Bl Bl
Y Y
Y Y
Y Y
/YBl /YBl Bl/Y
G/W G/W G/W
B B
O O
Bl Bl Bl
Bl Bl Bl
O O
Y Y
W W
B/W B/W B/W
Y/B Y/B Y/B
Lbl Lb Lbl
B B
Lg Lg Lg
O O
W W
Y Y
Y/W Y/W Y/W
B/W B/W B/W
B/Y B/Y B/Y
Lbl Lb Lbl
B B
Lg Lg Lg
O O
B/Bl B/Bl B/Bl
WIRE ROUTING
SERVICING INFORMATION 7-11
7-12 SERVICING INFORMATION
ENGINE ELECTRICAL PARTS WIRE ROUTING
CABLE ROUTING
SERVICING INFORMATION 7-13
7-14 SERVICING INFORMATION
FRONT BRAKE HOSE ROUTING
Front brake hose
VIEW OF TOP
42˚
VIEW OF FRONT
20˚
23 N.m
(2.3 kgf-m)
Throttle cable
Pass through the brake hose behind the throttle cable.
Clamp the brake hose firmly.
Clamp the brake hose firmly.
After the brake hose union has contacted the stopper, tighten the union bolt.
23 N.m
(2.3 kgf-m)
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING
SERVICING INFORMATION 7-15
PAIR pipe
PAIR pipe
Vacuum hose
Vacuum hose
PAIR valve
PAIR valve
PAIR hose
PAIR hose
Matching mark
Matching mark
PAIR valve
PAIR valve
PAIR cleaner hose
PAIR cleaner hose
7-16 SERVICING INFORMATION
SPEEDOMETER CABLE ROUTING
A
A
45˚
Cable guide
Cable guide
Protrusion (Gearbox)
SIDE-STAND INSTALLATION
Speedometer cable
Stopper (Fork)
40 N.m
(4.0 kgf-m)
Side-stand
SERVICING INFORMATION 7-17
FUEL TANK INSTALLATION
Cushion
Clamp
Cushion
Fuel valve
Align the cushion concave part with the frame locating plate.
Bolt
Install so that the clamp claw faces downward.
Cushion
Spacer
Cushion
Install so that the clamp claw faces inward.
Cut the clamp end, so the remaining part should be more or less 10 mm.
Gasket To carburetor
4.5 N.m
(0.45 kgf-m)
REAR BRAKE PEDAL INSTALLTAION
Brake pedal height:
Approx. 11 mm
Rear brake light switch
Snap ring
Cotter pin (Bend the cotter pin and its ends should face downward.)
7-18 SERVICING INFORMATION
DRIVE CHAIN GUIDE ROLLER INSTALLATION
Frame
36 – 44 N.m
(3.6 – 4.4 kgf-m)
HANDLEBAR BALANCER INSTALLATION
Throttle grip
Balancer weight
4.0 – 7.0 N.m
(0.4 – 0.7 kgf-m)
EXHAUST PIPE AND MUFFLER INSTALLATION
. m
SERVICING INFORMATION 7-19
. m
. m
. m
7-20 SERVICING INFORMATION
CARBURETOR AND AIR CLEANER INSTALLATION
Forward
LH
Intake pipe side
RH LH
40˚ – 50˚
Air cleaner side
RH
Carburetor air vent hose
PAIR hose
Carburetor overflow hose
Crankcase breather hose
(PCV hose)
PAIR pipe
Vacuum hose
Carburetor overflow hose
PAIR valve
Carburetor overflow hose
SERVICING INFORMATION 7-21
SPECIAL TOOLS
09900-00401
Hexagon wrench set
09900-00410
Hexagon wrench set
09900-06107
Snap ring pliers
09900-09004
Impact driver set
09900-18710
Hexagon socket
(12 mm)
09900-20101
Vernier calipers
09900-20102
Vernier calipers
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
(1/100 mm,
10 – 34 mm)
09900-20606
Dial gauge
(1/100 mm)
09900-20701
Magnetic stand
09900-20803
Thickness gauge
09900-20805
Tire depth gauge
09900-21304
V-block set
(100 mm)
09900-22301
Plastigauge
09900-22302
Plastigauge
09900-22403
Small bore gauge
(10 – 18 mm)
09900-25008
Multi circuit tester set
09900-26006
Tachometer
09910-20116
Conrod holder
09910-32812
Crankshaft installer
09910-34510
Piston pin puller
7-22 SERVICING INFORMATION
09913-10750
Adapter
09913-10760
Fuel level gauge set
09913-50121
Oil seal remover
09913-70210
Bearing installer set
09915-63210
Compression gauge adaptor
09915-64510
Compression gauge set
09915-70610
Adaptor
09915-74510
Oil pressure gauge set
09916-10911
Valve lapper set
09916-14510
Valve lifter
09916-14910
Attachment
09916-20620
Valve seat cutter
(N-122)
09916-21111
Valve seat cutter set
09916-24920
Valve seat cutter
(N-212)
09916-24480
Solid pilot
(N-140-5.5)
09916-34542
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
Tweezers
09917-13210
Valve adjuster wrench
09917-47010
Vacuum pump gauge
09920-13120
Crankcase separating tool
09920-53740
Clutch sleeve hub holder
09921-20210
Bearing puller
SERVICING INFORMATION 7-23
09921-20240
Bearing remover set
09923-74510
Bearing remover
09924-84521
Bearing installer set
09930-10121
Spark plug wrench set
09930-11920
Torx bit JT40H
09930-11940
Bit holder
09930-30102
Sliding shaft
09930-34932
Rotor remover
09930-44530
Rator holder
09940-14911
Steering stem nut socket wrench
09940-34520
“T” handle
09940-34561
Attachment “D”
09940-52861
Front fork oil seal installer
09940-60113
Spoke nipple wrench
09941-34513
Bearing installer
09941-50111 wheel bearing remover
09941-54911
Bearing outer race remover
09941-74911
Bearing installer
09943-74111
Fork oil level gauge
NOTE:
When ordering a special tool, please confirm whether it is available or not.
7-24 SERVICING INFORMATION
TIGHTENING TORQUE
ENGINE
Cylinder head cover bolt
Cylinder head nut
ITEM
8 mm
6 mm
Cylinder base nut
Primary drive gear nut
Crankcase bolt
Exhaust pipe bolt
Muffler mounting bolt
Muffler connecting bolt
Cam chain tension adjuster bolt
Camshaft sprocket bolt
Rocker arm shaft bolt
Clutch sleeve hub nut
Clutch spring set bolt
Clutch cover bolt
Generator cover bolt
Generator rotor nut
Generator cover plug
Starter clutch bolt
Gearshift cam stopper bolt
Timing inspection plug
Valve clearance adjust screw lock nut
Oil strainer cap bolt
Oil gallery plug
Oil drain plug
Initial
Final
11
26
11
21
5
10
10
55
15
10
23
28
7
11
9
50
11
23
23
20
N·m
10
10
23
10
10
50
1.1
2.6
1.1
2.1
0.5
1.0
1.0
5.5
1.5
1.0
2.3
2.8
0.7
1.1
0.9
5.0
1.1
2.3
2.3
2.0
kgf-m
1.0
1.0
2.3
1.0
1.0
5.0
CHASSIS
ITEM
Front axle nut
Front axle pinch bolt
Front fork cap bolt
Front fork damper rod bolt
Front fork lower clamp bolt
Front fork upper clamp bolt
Steering stem head nut
Steering stem nut
Handlebar clamp bolt
Front brake master cylinder mounting bolt
Front brake caliper mounting bolt
Front brake hose union bolt
Air bleeder valve
Brake disc bolt
Front footrest bolt
Swingarm pivot nut
Rear shock absorber mounting bolt/nut
(Upper & Lower)
Rear axle nut
Rear sprocket mounting nut
Rear brake cam lever nut
50
65
60
7
39
23
7.5
23
90
45
23
10
94
65
N·m
65
23
23
30
33
23
SERVICING INFORMATION 7-25
9.0
4.5
2.3
1.0
3.9
2.3
0.75
2.3
9.4
6.5
kgf-m
6.5
2.3
2.3
3.0
3.3
2.3
5.0
6.5
6.0
0.7
7-26 SERVICING INFORMATION
TIGHTENING TORQUE CHART
For other nuts and bolts not listed in the preceding page, refer to this chart:
Bolt Diameter
A (mm)
8
10
12
14
4
5
6
16
18
Conventional or “4” marked bolt
N·m
1.5
kgf-m
0.15
3
5.5
13
29
0.3
0.55
1.3
2.9
45
65
105
160
4.5
6.5
10.5
16.0
N·m
2.3
“7” marked bolt kgf-m
0.23
4.5
10
23
50
0.45
1.0
2.3
5.0
85
135
210
240
8.5
13.5
21.0
24.0
A
Conventional bolt “4” marked bolt
“7” marked bolt
SERVICING INFORMATION 7-27
SERVICE DATA
VALVE + GUIDE
ITEM
Valve diam.
Valve clearance (when cold)
Valve guide to valve stem clearance
Valve guide I.D.
Valve stem O.D.
Valve stem deflection
Valve stem runout
Valve head thickness
Valve stem end length
Valve seat width
Valve head radial runout
Valve spring free length
(IN. & EX.)
Valve spring tension
(IN. & EX.)
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
Camshaft runout
Rocker arm I.D.
Rocker arm shaft O.D.
Cylinder head distortion
Cylinder head cover distortion
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN.
EX.
IN.
EX.
IN.
EX.
IN. & EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
INNER
OUTER
INNER
OUTER
STANDARD
30
26
0.08 – 0.13
0.13 – 0.18
0.010 – 0.037
0.030 – 0.057
5.500 – 5.512
5.475 – 5.490
5.455 – 5.470
—
—
—
—
0.9 – 1.1
—
—
—
76 – 90 N (7.8 – 9.2 kgf) at length 32.5 mm
186 – 219 N (18.9 – 22.3 kgf) at length 36.0 mm
STANDARD
34.17 – 34.22
33.80 – 33.85
0.032 – 0.066
22.012 – 22.025
21.959 – 21.980
—
12.000 – 12.018
11.977 – 11.995
—
—
0.35
0.05
0.5
2.5
—
—
—
—
Unit: mm
LIMIT
—
—
—
—
—
—
0.03
36.8
40.1
—
—
Unit: mm
LIMIT
33.87
33.50
0.150
—
—
0.10
—
—
0.05
0.05
7-28 SERVICING INFORMATION
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
STANDARD
1 300 – 1 700 kPa
(13 – 17 kgf/cm 2 , 185 – 242 psi)
Piston-to-cylinder clearance
Cylinder bore
Piston diam.
Cylinder distortion
Piston ring free end gap
Piston ring end gap
Piston ring to groove clearance
Piston ring groove width
Piston ring thickness
Piston pin bore
Piston pin O.D.
2nd
1st
2nd
1st
2nd
Oil
1st
2nd
0.040 – 0.055
57.000 – 57.015
1st
2nd
1st
56.955 – 56.970
Measure at 8 mm from the skirt end.
—
R
R
Approx. 7.2
Approx. 5.0
0.20 – 0.32
0.20 – 0.32
—
—
1.01 – 1.03
1.01 – 1.03
2.01 – 2.03
0.970 – 0.990
0.970 – 0.990
14.002 – 14.008
13.992 – 14.000
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
Crankshaft runout
OIL PUMP
ITEM
Oil pressure (at 60 °C, 140 °F)
STANDARD
14.006 – 14.014
—
0.10 – 0.45
15.95 – 16.00
53.0 ± 0.1
—
STANDARD
Above 15 kPa (0.15 kgf/cm 2
Below 35 kPa (0.35 kgf/cm 2 )
) at 3 000 r/min.
CLUTCH
ITEM
Clutch lever play
Drive plate thickness
Drive plate claw width
Driven plate distortion
Clutch spring free length
STANDARD
10 – 15
2.95 – 3.15
11.8 – 12.0
—
32.6
Unit: mm
LIMIT
980 kPa
(9.8 kgf/cm 2 ,
140 psi)
0.120
57.090
56.880
0.05
5.8
4.0
0.7
0.7
0.18
0.15
—
—
—
—
—
14.030
13.980
Unit: mm
LIMIT
14.040
3.0
1.0
—
—
0.08
LIMIT
—
Unit: mm
LIMIT
—
2.65
11.5
0.10
31.0
SERVICING INFORMATION 7-29
DRIVE TRAIN + DRIVE CHAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios Low
2nd
3rd
4th
Shift fork to groove clearance
Shift fork groove width
5th
Top
Shift fork thickness
No. 1
No. 2
No. 1
No. 2
Countershaft length
(Low to 2nd)
Drive chain Type
Links
20-pitch length
Drive chain slack
Gearshift lever height
STANDARD
3.470 (59/17)
3.400 (51/15)
3.000 (33/11)
1.857 (26/14)
1.368 (26/19)
1.095 (23/21)
0.923 (24/26)
0.833 (20/24)
0.10 – 0.30
5.0 – 5.1
5.5 – 5.6
4.8 – 4.9
5.3 – 5.4
88.0
+0.1
-0
DID 428
132
—
15 – 25
20
(between footrest top and gearshift lever top)
Unit: mm Except ratio
—
—
0.50
—
—
—
—
LIMIT
—
—
—
—
—
—
—
—
—
259.0
—
—
PAIR SYSTEM
ITEM
Negative pressure range
CARBURETOR
STANDARD
–37.3 – –60.0 kPa (–280 – –450 mmHg)
LIMIT
—
ITEM
Carburetor type
Bore size
I.D. No
Idle r/min.
Float height
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Pilot screw
Throttle cable play
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(P.S.)
SPECIFICATION
E-02, 19
MIKUNI BS26
26 mm
13GA
1 500 ± 100 r/min
17.1 ± 1.0 mm
# 115
4EJ44-2nd
P-0M
# 105
# 15
PRE-SET (2 turns out)
2.0 – 4.0 mm
7-30 SERVICING INFORMATION
ELECTRICAL
Spark plug
ITEM
Spark performance
Ignition coil resistance
Generator coil resistance
Pick-up coil peak voltage
Ignition coil primary peak voltage
Pick-up coil resistance
Generator no-load voltage
(when engine is cold)
Regulated voltage
Starter relay resistance
Battery Type designation
Capacity
Fuse size
WATTAGE
ITEM
Headlight HI
LO
Position light
Brake light/Taillight
Turn signal light
Speedometer light
Turn signal indicator light
High beam indicator light
Neutral indicator light
Type
Gap
Primary
Secondary
SPECIFICATION
DENSO: U24ESR-N
NGK: CR8E
0.7 – 0.8 mm
Over 8 mm at 1 atm.
1.6 – 2.7
Ω
18 – 26 k
Ω
0.4 – 0.8
Ω
∞ Ω
More than 2.0 V
More than 200 V
172 – 288
Ω
∞ Ω
More than 60 V (AC) at 5 000 r/min
14.0 – 15.5 V at 5 000 r/min
3 – 6 Ω
YTX7L-BS
12 V 21.6 kC (6 Ah)/10 HR
20 A
E-02
60
55
5
21/5
21
1.7
3.4
1.7
3.4
STANDARD/SPECIFICATION
E-19
←
←
4
←
←
←
←
←
←
NOTE
+ tap –
tap
Plug cap –
+
tap
B – B
Ground – B
+ : Bl, : B/W
+
: Bl,
-
: G
+ : B, : Ground
G – Bl
G – Ground
Unit: W
SERVICING INFORMATION 7-31
BRAKE + WHEEL
ITEM
Rear brake pedal free travel
Rear brake pedal height
Brake drum I.D.
Brake disc thickness
Brake disc runout
Master cylinder bore
Master cylinder piston diam.
Brake caliper cylinder bore
Brake caliper piston diam.
Brake fluid type
Wheel rim runout
Wheel axle runout
Wheel rim size
Tire size
Tire tread depth
Front
Rear
Front
Rear
Front
Rear
Rear
Front
Front
Front
Front
Front
Front
Axial
Radial
Front
Rear
STANDARD/SPECIFICATION
20 – 30
5 – 15
—
4.0 ± 0.2
—
12.700 – 12.743
12.657 – 12.684
30.230 – 30.306
30.150 – 30.200
DOT 4
—
—
—
—
18 M/C × MT 2.50
14 M/C × MT 4.50
130/80-18 M/C 66P
180/80-14 M/C 78P
—
—
SUSPENSION
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level
Front fork oil type
Front fork oil capacity (each leg)
Rear wheel travel
Swingarm pivot shaft runout
TIRE PRESSURE
COLD INFLATION TIRE PRESSURE
(SOLO AND DUAL RIDING)
FRONT
REAR
STANDARD/SPECIFICATION
110
382.9
171
SUZUKI FORK OIL #10 or an equivalent fork oil
230 ml
136
— kPa
125
125 kgf/cm 2
1.25
1.25
Unit: mm
LIMIT
—
375
—
—
—
—
0.6
Unit: mm
2.0
2.0
0.25
0.25
—
—
—
—
LIMIT
—
—
110.7
3.5
0.30
—
—
—
—
—
4.0
4.0
7-32 SERVICING INFORMATION
FUEL + OIL
ITEM
Fuel type
Fuel tank including
Engine oil type
Engine oil capacity reserve reserve
SPECIFICATION
Gasoline used should be graded 91 octane or higher. An unleaded gasoline type is recommended.
7.5 L
1.8 L
Change
SAE 10W-40, API SF or SG
850 ml
Filter change
Overhaul
950 ml
1 200 ml
NOTE
RV125K4/K5 (’04, ’05-MODELS) 8-1
RV125K4/K5 (’04, ’05-MODELS)
CONTENTS
REAR FENDER INSTALLATION ................................................................. 8-10
8
8-2 RV125K4/K5 (’04, ’05-MODELS)
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ......................................................................................
2 140 mm (84.3 in)
Overall width .......................................................................................
860 mm (33.9 in)
Overall height ......................................................................................
1 120 mm (44.1 in)
Wheelbase ..........................................................................................
1 385 mm (54.5 in)
Ground clearance................................................................................
215 mm ( 8.5 in)
Seat height ..........................................................................................
770 mm (30.3 in)
Dry mass.............................................................................................
117 kg (257 lbs)
ENGINE
Type.....................................................................................................
Four-stroke, air-cooled, OHC
Number of cylinders ............................................................................
1
Bore ....................................................................................................
57.0 mm (2.244 in)
Stroke..................................................................................................
48.8 mm (1.921 in)
Displacement ......................................................................................
125 cm 3 (7.6 cu. in)
Compression ratio ...............................................................................
9.2 : 1
Carburetor ...........................................................................................
MIKUNI BS26
Air cleaner ...........................................................................................
Polyurethane foam element
Starter system.....................................................................................
Electric
Lubrication system ..............................................................................
Wet sump
Idle speed ...........................................................................................
1 500 ± 100 r/min
DRIVE TRAIN
Clutch ..................................................................................................
Wet multi-plate type
Transmission .......................................................................................
6-speed constant mesh
Gearshift pattern .................................................................................
1-down, 5-up
Primary reduction ratio........................................................................
3.470 (59/17)
Gear ratios, Low ...............................................................................
3.000 (33/11)
2nd ...............................................................................
1.857 (26/14)
3rd ................................................................................
1.368 (26/19)
4th ................................................................................
1.095 (23/21)
5th ................................................................................
0.923 (24/26)
Top................................................................................
0.833 (20/24)
Final reduction ratio.............................................................................
3.400 (51/15)
Drive chain ..........................................................................................
D.I.D. 428, 134 links
CHASSIS
Front suspension.................................................................................
Telescopic, coil spring, oil damped
Rear suspension .................................................................................
Swingarm type, coil spring, oil damped
Front suspension stroke ......................................................................
110 mm (4.3 in)
Rear wheel travel ................................................................................
136 mm (5.4 in)
Caster .................................................................................................
26°
Trail......................................................................................................
91 mm (3.6 in)
Steering angle .....................................................................................
45° (right & left)
Turning radius .....................................................................................
2.1 m (6.9 ft)
Front brake ..........................................................................................
Disc brake
Rear brake ..........................................................................................
Drum brake
Front tire size ......................................................................................
130/80-18 M/C 66P, tube type
Rear tire size .......................................................................................
180/80-14 M/C 78P, tube type
ELECTRICAL
Ignition type.........................................................................................
Electronic ignition (Transistorized)
Ignition timing ......................................................................................
13° B.T.D.C. at 1 500 r/min
Spark plug ...........................................................................................
NGK CR8E or DENSO U24ESR-N
Battery.................................................................................................
12 V 21.6 kC (6 Ah)/10 HR
Generator ............................................................................................
Three-phase A.C. generator.
Fuse ....................................................................................................
20 A
Headlight .............................................................................................
12 V 60/55 W
Brake light/Taillight ..............................................................................
12 V 21/5 W
Position light ........................................................................................
12 V 4 W ..............................E-19
12 V 5 W .............................. E-02
Turn signal light ...................................................................................
12 V 21 W
Speedometer light ...............................................................................
12 V 1.7 W
Neutral indicator light ..........................................................................
12 V 3.4 W
High beam indicator light ....................................................................
12 V 1.7 W
Turn signal indicator light ....................................................................
12 V 3.4 W
CAPACITIES
Fuel tank, including reserve ..............................................................
7.5 L (2.0/1.6 US/Imp gal)
Reserve............................................................................
1.8 L (0.5/0.4 US/Imp gal)
Engine oil, oil change ........................................................................
850 ml (0.9/0.7 US/Imp qt) filter change.....................................................................
950 ml (1.0/0.8 US/Imp qt) overhaul...........................................................................
1 200 ml (1.3/1.1 US/Imp qt)
RV125K4/K5 (’04, ’05-MODELS) 8-3
SERVICE DATA
VALVE + GUIDE
ITEM
Valve diam.
Valve clearance (when cold)
Valve guide to valve stem clearance
Valve guide I.D.
Valve stem O.D.
Valve stem deflection
Valve stem runout
Valve head thickness
Valve stem end length
Valve seat width
Valve head radial runout
Valve spring free length
(IN. & EX.)
Valve spring tension
(IN. & EX.)
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
Camshaft runout
Rocker arm I.D.
Rocker arm shaft O.D.
Cylinder head distortion
Cylinder head cover distortion
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN.
EX.
IN.
EX.
IN.
EX.
IN. & EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
INNER
OUTER
INNER
OUTER
STANDARD
30
26
0.08 – 0.13
0.13 – 0.18
0.010 – 0.037
0.030 – 0.057
5.500 – 5.512
5.475 – 5.490
5.455 – 5.470
—
—
—
—
0.9 – 1.1
—
—
—
76 – 90 N (7.8 – 9.2 kgf) at length 32.5 mm
186 – 219 N (18.9 – 22.3 kgf) at length 36.0 mm
STANDARD
34.17 – 34.22
33.80 – 33.85
0.032 – 0.066
22.012 – 22.025
21.959 – 21.980
—
12.000 – 12.018
11.977 – 11.995
—
—
—
0.35
0.05
0.5
—
—
—
—
Unit: mm
LIMIT
—
—
—
—
2.5
—
0.03
36.8
40.1
—
—
—
0.10
—
—
0.05
0.05
Unit: mm
LIMIT
33.87
33.50
0.150
—
8-4 RV125K4/K5 (’04, ’05-MODELS)
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
STANDARD
1 300 – 1 700 kPa
(13 – 17 kgf/cm 2 , 185 – 242 psi)
Piston-to-cylinder clearance
Cylinder bore
Piston diam.
Cylinder distortion
Piston ring free end gap
Piston ring end gap
Piston ring to groove clearance
Piston ring groove width
Piston ring thickness
Piston pin bore
Piston pin O.D.
2nd
1st
2nd
1st
2nd
Oil
1st
2nd
0.040 – 0.055
57.000 – 57.015
1st
2nd
1st
56.955 – 56.970
Measure at 8 mm from the skirt end.
—
R
R
Approx. 7.2
Approx. 5.0
0.20 – 0.32
0.20 – 0.32
—
—
1.01 – 1.03
1.01 – 1.03
2.01 – 2.03
0.970 – 0.990
0.970 – 0.990
14.002 – 14.008
13.992 – 14.000
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
Crankshaft runout
OIL PUMP
ITEM
Oil pressure (at 60 °C, 140 °F)
STANDARD
14.006 – 14.014
—
0.10 – 0.45
15.95 – 16.00
53.0 ± 0.1
—
STANDARD
Above 15 kPa (0.15 kgf/cm 2 )
Below 35 kPa (0.35 kgf/cm 2 ) at 3 000 r/min
CLUTCH
ITEM
Clutch lever play
Drive plate thickness
Drive plate claw width
Driven plate distortion
Clutch spring free length
STANDARD
10 – 15
2.95 – 3.15
11.8 – 12.0
—
32.6
Unit: mm
LIMIT
980 kPa
(9.8 kgf/cm 2 ,
140 psi)
0.120
57.090
56.880
0.05
5.8
4.0
0.7
0.7
0.18
0.15
—
—
—
—
—
14.030
13.980
Unit: mm
LIMIT
14.040
3.0
1.0
—
—
0.08
LIMIT
—
Unit: mm
LIMIT
—
2.65
11.5
0.10
31.0
RV125K4/K5 (’04, ’05-MODELS) 8-5
DRIVE TRAIN + DRIVE CHAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios Low
2nd
3rd
4th
Shift fork to groove clearance
Shift fork groove width
5th
Top
Shift fork thickness
No. 1
No. 2
No. 1
No. 2
Countershaft length
(Low to 2nd)
Drive chain Type
Links
20-pitch length
Drive chain slack
Gearshift lever height
STANDARD
3.470 (59/17)
3.400 (51/15)
3.000 (33/11)
1.857 (26/14)
1.368 (26/19)
1.095 (23/21)
0.923 (24/26)
0.833 (20/24)
0.10 – 0.30
5.0 – 5.1
5.5 – 5.6
4.8 – 4.9
5.3 – 5.4
88.0
+0.1
-0
DID 428
132
—
15 – 25
20
(between footrest top and gearshift lever top)
Unit: mm (Except ratio)
LIMIT
—
—
—
—
0.50
—
—
—
—
—
—
—
—
—
—
—
259.0
—
—
PAIR SYSTEM
ITEM
Negative pressure range
STANDARD
–37.3 – –60.0 kPa (–280 – –450 mmHg)
LIMIT
—
CARBURETOR
ITEM
Carburetor type
Bore size
I.D. No
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Pilot screw
Throttle cable play
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(P.S.)
SPECIFICATION
E-02, 19
MIKUNI BS26
26 mm
13GA
1 500 ± 100 r/min
17.1 ± 1.0 mm
# 115
4EJ44-2nd
P-0M
# 105
# 15
PRE-SET (2 turns out)
2.0 – 4.0 mm
8-6 RV125K4/K5 (’04, ’05-MODELS)
ELECTRICAL
Spark plug
ITEM
Spark performance
Ignition coil resistance
Generator coil resistance
Pick-up coil peak voltage
Ignition coil primary peak voltage
Pick-up coil resistance
Generator no-load voltage
(when engine is cold)
Regulated voltage
Starter relay resistance
Battery Type designation
Capacity
Fuse size
WATTAGE
ITEM
Headlight HI
LO
Position light
Brake light/Taillight
Turn signal light
Speedometer light
Turn signal indicator light
High beam indicator light
Neutral indicator light
Type
Gap
Primary
Secondary
SPECIFICATION
DENSO: U24ESR-N
NGK: CR8E
0.7 – 0.8 mm
Over 8 mm at 1 atm.
1.6 – 2.7 Ω
18 – 26 k
Ω
0.4 – 0.8 Ω
∞ Ω
More than 2.0 V
More than 200 V
172 – 288
Ω
∞ Ω
More than 60 V (AC) at 5 000 r/min
14.0 – 15.5 V at 5 000 r/min
3 – 6
Ω
YTX7L-BS
12 V 21.6 kC (6 Ah)/10 HR
20 A
E-02
STANDARD/SPECIFICATION
60
55
5
21/5
21
1.7
3.4
1.7
3.4
E-19
←
←
4
←
←
←
←
←
←
NOTE
+
tap –
tap
Plug cap –
+ tap
B – B
Ground – B
+ : Bl, : B/W
+ : Bl, : G
+ : B, :
Ground
G – Bl
G – Ground
Unit: W
RV125K4/K5 (’04, ’05-MODELS) 8-7
BRAKE + WHEEL
ITEM
Rear brake pedal free travel
Rear brake pedal height
Brake drum I.D.
Brake disc thickness
Brake disc runout
Master cylinder bore
Master cylinder piston diam.
Brake caliper cylinder bore
Brake caliper piston diam.
Brake fluid type
Wheel rim runout
Wheel axle runout
Wheel rim size
Tire size
Tire tread depth
Front
Rear
Front
Rear
Front
Rear
Rear
Front
Front
Front
Front
Front
Front
Axial
Radial
Front
Rear
STANDARD/SPECIFICATION
20 – 30
5 – 15
—
4.0 ± 0.2
—
12.700 – 12.743
12.657 – 12.684
30.230 – 30.306
30.150 – 30.200
DOT 4
—
—
—
—
18 M/C × MT 2.50
14 M/C × MT 4.50
130/80-18 M/C 66P
180/80-14 M/C 78P
—
—
SUSPENSION
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level
Front fork oil type
Front fork oil capacity (each leg)
Rear wheel travel
Swingarm pivot shaft runout
STANDARD/SPECIFICATION
110
382.9
171
SUZUKI FORK OIL #10 or an equivalent fork oil
230 ml
136
—
TIRE PRESSURE
COLD INFLATION TIRE PRESSURE
(SOLO AND DUAL RIDING)
FRONT
REAR kPa
125
125 kgf/cm 2
1.25
1.25
Unit: mm
LIMIT
—
375
—
—
—
—
0.6
0.25
0.25
—
—
—
—
4.0
4.0
0.30
—
—
—
—
—
2.0
2.0
Unit: mm
LIMIT
—
—
110.7
3.5
8-8 RV125K4/K5 (’04, ’05-MODELS)
FUEL + OIL
ITEM
Fuel type
Fuel tank including
Engine oil type
Engine oil capacity reserve reserve
SPECIFICATION
Gasoline used should be graded 91 octane or higher. An unleaded gasoline type is recommended.
7.5 L
1.8 L
Change
SAE 10W-40, API SF or SG
850 ml
Filter change
Overhaul
950 ml
1 200 ml
NOTE
WIRE ROUTING
RV125K4/K5 (’04, ’05-MODELS) 8-9
8-10 RV125K4/K5 (’04, ’05-MODELS)
REAR FENDER INSTALLATION
6.5 N.m
(0.65 kgf-m)
RV125K6 (’06-MODEL)
RV125K6 (’06-MODEL) 9-1
This chapter describes service specifications, service data and servicing procedurers which differ from those of the RV125K4/K5 (’04, ’05-MODEL).
NOTE:
* Any differences between the RV125K4/K5 (’04, ’05-MODEL) and RV125K6 (’06-MODEL) in specifications are cleary indicated with an asterisk (*) mark.
* Please refer to the chapters 1 through 8 for details which are not given in this chapter.
CONTENTS
9
9-2 RV125K6 (’06-MODEL)
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ...................................................................................... 2 140 mm (84.3 in)
Overall width ....................................................................................... 860 mm (33.9 in)
Overall height ...................................................................................... 1 120 mm (44.1 in)
Wheelbase .......................................................................................... 1 385 mm (54.5 in)
Ground clearance................................................................................ 215 mm ( 8.5 in)
Seat height .......................................................................................... 770 mm (30.3 in)
Dry mass............................................................................................. 117 kg (257 lbs)
ENGINE
Type..................................................................................................... Four-stroke, air-cooled, OHC
Number of cylinders ............................................................................ 1
Bore .................................................................................................... 57.0 mm (2.244 in)
Stroke.................................................................................................. 48.8 mm (1.921 in)
Displacement ...................................................................................... 125 cm 3 (7.6 cu. in)
Compression ratio ............................................................................... 9.2 : 1
Carburetor ........................................................................................... MIKUNI BS26
Air cleaner ........................................................................................... Polyurethane foam element
Starter system..................................................................................... Electric
Lubrication system .............................................................................. Wet sump
Idle speed ........................................................................................... 1 500 ± 100 r/min
DRIVE TRAIN
Clutch .................................................................................................. Wet multi-plate type
Transmission ....................................................................................... 6-speed constant mesh
Gearshift pattern ................................................................................. 1-down, 5-up
Primary reduction ratio........................................................................ 3.470 (59/17)
Gear ratios, Low ................................................................................. 3.000 (33/11)
2nd.................................................................................. 1.857 (26/14)
3rd .................................................................................. 1.368 (26/19)
4th................................................................................... 1.095 (23/21)
5th................................................................................... 0.923 (24/26)
Top .................................................................................. 0.833 (20/24)
Final reduction ratio............................................................................. 3.400 (51/15)
Drive chain .......................................................................................... D.I.D. 428, 134 links
CHASSIS
Front suspension................................................................................. Telescopic, coil spring, oil damped
Rear suspension ................................................................................. Swingarm type, coil spring, oil damped
Front suspension stroke ...................................................................... 110 mm (4.3 in)
Rear wheel travel ................................................................................ 136 mm (5.4 in)
Caster ................................................................................................. 26 °
Trail...................................................................................................... 91 mm (3.6 in)
Steering angle ..................................................................................... 45 ° (right & left)
Turning radius ..................................................................................... 2.1 m (6.9 ft)
Front brake .......................................................................................... Disc brake
Rear brake .......................................................................................... Drum brake
Front tire size ...................................................................................... 130/80-18 M/C 66P, tube type
Rear tire size ....................................................................................... 180/80-14 M/C 78P, tube type
ELECTRICAL
Ignition type......................................................................................... Electronic ignition (Transistorized)
Ignition timing ...................................................................................... 13 ° B.T.D.C. at 1 500 r/min
Spark plug ........................................................................................... NGK CR8E or DENSO U24ESR-N
Battery................................................................................................. 12 V 21.6 kC (6 Ah)/10 HR
Generator ............................................................................................ Three-phase A.C. generator
Fuse .................................................................................................... 20 A
Headlight ............................................................................................. 12 V 60/55 W
Brake light/Taillight .............................................................................. 12 V 21/5 W
Position light ........................................................................................ 12 V 4 W......E-19
12 V 5 W......E-02
Turn signal light ................................................................................... 12 V 21 W
Speedometer light ............................................................................... 12 V 1.7 W
Neutral indicator light .......................................................................... 12 V 3.4 W
High beam indicator light .................................................................... 12 V 1.7 W
Turn signal indicator light .................................................................... 12 V 3.4 W
CAPACITIES
Fuel tank, including reserve ............................................................... 7.5 L (2.0/1.6 US/Imp gal)
Reserve ............................................................................. 1.8 L (0.5/0.4 US/Imp gal)
Engine oil, oil change......................................................................... 850 ml (0.9/0.7 US/Imp qt) filter change ..................................................................... 950 ml (1.0/0.8 US/Imp qt) overhaul ........................................................................... 1 200 ml (1.3/1.1 US/Imp qt)
SERVICE DATA
VALVE + GUIDE
ITEM
Valve diam.
Valve clearance (when cold)
Valve guide to valve stem clearance
Valve guide I.D.
Valve stem O.D.
Valve stem deflection
Valve stem runout
Valve head thickness
Valve stem end length
Valve seat width
Valve head radial runout
Valve spring free length
(IN. & EX.)
Valve spring tension
(IN. & EX.)
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
Camshaft runout
Rocker arm I.D.
Rocker arm shaft O.D.
Cylinder head distortion
Cylinder head cover distortion
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN.
EX.
IN.
EX.
IN.
EX.
IN. & EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
INNER
OUTER
INNER
OUTER
STANDARD
25.5
22.5
0.03 – 0.08
0.13 – 0.18
0.010 – 0.037
0.030 – 0.057
5.000 – 5.012
4.975 – 4.990
4.955 – 4.970
—
—
—
—
0.9 – 1.1
—
—
—
38.1 – 43.9 N
(3.9 – 4.4 kgf) at length 26.78 mm
89.6 – 103 N
(9.1 – 10.5 kgf) at length 29.78 mm
STANDARD
33.620 – 33.660
33.300 – 33.340
0.032 – 0.066
22.012 – 22.025
21.959 – 21.980
—
12.000 – 12.018
11.977 – 11.995
—
—
RV125K6 (’06-MODEL) 9-3
—
0.35
0.05
0.5
—
—
—
—
Unit: mm
LIMIT
—
—
—
—
1.7
—
0.03
31.3
33.6
—
—
—
0.10
—
—
0.05
0.05
Unit: mm
LIMIT
33.32
33.00
0.150
—
9-4 RV125K6 (’06-MODEL)
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
STANDARD
1 100 – 1 500 kPa
(11 – 15 kgf/cm 2 )
Piston-to-cylinder clearance
Cylinder bore
Piston diam.
Cylinder distortion
Piston ring free end gap
Piston ring end gap
Piston ring to groove clearance
Piston ring groove width
Piston ring thickness
Piston pin bore
Piston pin O.D.
1st
2nd
1st
2nd
R
R
0.040 – 0.055
57.000 – 57.015
56.955 – 56.970
Measure at 8 mm from the skirt end.
—
Approx. 7.2
Approx. 5.0
0.20 – 0.32
0.20 – 0.32
1st
2nd
1st
2nd
Oil
1st
2nd
—
—
1.01 – 1.03
1.01 – 1.03
2.01 – 2.03
0.970 – 0.990
0.970 – 0.990
14.002 – 14.008
13.992 – 14.000
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
Crankshaft runout
OIL PUMP
ITEM
Oil pressure (at 60 °C, 140 °F)
STANDARD
14.006 – 14.014
—
0.10 – 0.45
15.95 – 16.00
53.0 ± 0.1
—
STANDARD
Above 15 kPa (0.15 kgf/cm 2 )
Below 35 kPa (0.35 kgf/cm 2 ) at 3 000 r/min
CLUTCH
ITEM
Clutch lever play
Drive plate thickness
Drive plate claw width
Driven plate distortion
Clutch spring free length
STANDARD
10 – 15
2.95 – 3.15
11.8 – 12.0
—
32.6
Unit: mm
LIMIT
800 kPa
(8.0 kgf/cm 2 )
0.120
57.090
56.880
—
—
—
—
—
14.030
13.980
0.05
5.8
4.0
0.7
0.7
0.18
0.15
Unit: mm
LIMIT
14.040
3.0
1.0
—
—
0.08
LIMIT
—
Unit: mm
LIMIT
—
2.65
11.5
0.10
31.0
RV125K6 (’06-MODEL) 9-5
DRIVE TRAIN + DRIVE CHAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios Low
2nd
3rd
4th
Shift fork to groove clearance
Shift fork groove width
5th
Top
Shift fork thickness
No. 1
No. 2
No. 1
No. 2
Countershaft length
(Low to 2nd)
Drive chain Type
Links
20-pitch length
Drive chain slack
Gearshift lever height
STANDARD
3.470 (59/17)
3.400 (51/15)
3.000 (33/11)
1.857 (26/14)
1.368 (26/19)
1.095 (23/21)
0.923 (24/26)
0.833 (20/24)
0.10 – 0.30
5.0 – 5.1
5.5 – 5.6
4.8 – 4.9
5.3 – 5.4
88.0
+0.1
-0
DID 428
134
—
15 – 25
20
(between footrest top and gearshift lever top)
Unit: mm (Except ratio)
LIMIT
—
—
—
—
0.50
—
—
—
—
—
—
—
—
—
—
—
259.0
—
—
PAIR SYSTEM
ITEM
Negative pressure range
CARBURETOR
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Pilot screw
Throttle cable play
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(P.S.)
STANDARD
–37.3 – –60.0 kPa (–280 – –450 mmHg)
SPECIFICATION
MIKUNI BS26
26 mm
13GA
1 500 ± 100 r/min
17.1 ± 1.0 mm
#115
4EJ44-2nd
P-0M
#105
#15
PRE-SET (2 turns out)
2.0 – 4.0 mm
LIMIT
—
9-6 RV125K6 (’06-MODEL)
ELECTRICAL
Spark plug
ITEM
Spark performance
Ignition coil resistance
Generator coil resistance
Pick-up coil peak voltage
Ignition coil primary peak voltage
Pick-up coil resistance
Generator no-load voltage
(when engine is cold)
Regulated voltage
Starter relay resistance
Battery Type designation
Capacity
Fuse size
WATTAGE
ITEM
Headlight HI
LO
Position light
Brake light/Taillight
Turn signal light
Speedometer light
Turn signal indicator light
High beam indicator light
Neutral indicator light
Type
Gap
Primary
Secondary
SPECIFICATION
DENSO: U24ESR-N
NGK: CR8E
0.7 – 0.8 mm
Over 8 mm at 1 atm.
1.6 – 2.7
Ω
18 – 26 k Ω
0.4 – 0.8
Ω
∞ Ω
More than 2.0 V
More than 200 V
172 – 288 Ω
∞ Ω
More than 60 V (AC) at 5 000 r/min
14.0 – 15.5 V at 5 000 r/min
3 – 6
Ω
YTX7L-BS
12 V 21.6 kC (6 Ah)/10 HR
20 A
E-02
60
55
5
21/5
21
1.7
3.4
1.7
3.4
STANDARD/SPECIFICATION
E-19
←
←
4
←
←
←
←
←
←
NOTE
+
tap –
-
tap
Plug cap –
+ tap
B – B
Ground – B
+ : Bl, : B/W
+ : Bl, : G
+ : B, :
Ground
G – Bl
G – Ground
Unit: W
RV125K6 (’06-MODEL) 9-7
BRAKE + WHEEL
ITEM
Rear brake pedal free travel
Rear brake pedal height
Brake drum I.D.
Brake disc thickness
Brake disc runout
Master cylinder bore
Master cylinder piston diam.
Brake caliper cylinder bore
Brake caliper piston diam.
Brake fluid type
Wheel rim runout
Wheel axle runout
Wheel rim size
Tire size
Tire tread depth
SUSPENSION
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level
Front fork oil type
Front fork oil capacity (each leg)
Rear wheel travel
Swingarm pivot shaft runout
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
(SOLO AND DUAL RIDING)
FRONT
REAR
Front
Rear
Front
Rear
Front
Rear
Rear
Front
Front
Front
Front
Front
Front
Axial
Radial
Front
Rear
STANDARD/SPECIFICATION
20 – 30
5 – 15
—
4.0 ± 0.2
—
12.700 – 12.743
12.657 – 12.684
30.230 – 30.306
30.150 – 30.200
DOT 4
—
—
—
—
18 M/C × MT 2.50
14 M/C × MT 4.50
130/80-18 M/C 66P
180/80-14 M/C 78P
—
—
STANDARD/SPECIFICATION
110
382.9
171
SUZUKI FORK OIL #10 or an equivalent fork oil
230 ml
136
— kPa
125
125 kgf/cm 2
1.25
1.25
0.25
0.25
—
—
—
—
4.0
4.0
0.30
—
—
—
—
—
2.0
2.0
Unit: mm
LIMIT
—
—
110.7
3.5
Unit: mm
LIMIT
—
375
—
—
—
—
0.6
9-8 RV125K6 (’06-MODEL)
FUEL + OIL
ITEM
Fuel type
Fuel tank capacity
Engine oil type
Engine oil capacity including reserve reserve
SPECIFICATION
Gasoline used should be graded 91 octane or higher. An unleaded gasoline type is recommended.
7.5 L
1.8 L
* SAE 10W-40, API SF/SG or SH/SJ with JASO MA
Change
Filter change
Overhaul
850 ml
950 ml
1 200 ml
NOTE
Prepared by
2nd Ed. January, 2006
1st Ed. January, 2003
Part No. 99500-31233-01E
Printed in Japan
256
Printed in Japan
K3 K4 K5 K6

Public link updated
The public link to your chat has been updated.
Advertisement
Key features
- 125cc, air-cooled, 4-stroke engine provides excellent fuel economy and performance
- Comfortable upright riding position for all-day riding comfort
- Lightweight and easy to maneuver, making it perfect for city riding
- Reliable and durable, with a proven track record of performance
- Stylish and modern design that turns heads wherever you go