Suzuki DR650SE Shop Manual

FOREWORD

This manual contains an introductory description on SUZUKI DR650SE and procedures for its inspection/service and overhaul of its main components.

Other information considered as generally known is not included.

Read GENERAL INFORMATION section to familiarize yourself with outline of the vehicle and MAIN-

TENANCE and other sections to use as a guide for proper inspection and service.

This manual will help you know the vehicle better so that you can assure your customers of your optimum and quick service.

* This manual has been prepared on the basis of the latest specification at the time of publication.

If modification has been made since then, differences may exist between the content of this manual and the actual vehicle.

* Illustrations in this manual are used to show the basic principles of operation and work procedures.

They may not represent the actual vehicle exactly in detail.

* This manual is intended for those who have enough knowledge and skills for servicing

SUZUKI vehicles. Without such knowledge and skills, you should not attempt servicing by relying on this manual only.

Instead, please contact your nearby authorized SUZUKI motorcycle dealer.

IMPORTANT

All street-legal Suzuki motorcycles with engine displacement of 50cc or greater are subject to

Environmental Protection agency emission regulations. These regulations set specific standards for exhaust emission output levels as well as particular servicing requirements. This manual includes specific information required to properly inspect and service DR650SE in accordance with all EPA regulations. It is strongly recommended that the chapter on Emission Control, Periodic Servicing and Carburetion be thoroughly reviewed before any type of service work is performed.

Further information concerning the EPA emission regulations and U.S. Suzuki’s emission control program can be found in the U.S. SUZUKI EMIS-

SION CONTROL PROGRAM MANUAL/SERVICE

BULLETIN.

GROUP INDEX

GENERAL INFORMATION

PERIODIC MAINTENANCE

ENGINE

FUEL AND LUBRICATION

SYSTEM

CHASSIS

ELECTRICAL SYSTEM

SERVICING INFORMATION

EMISSION CONTROL

INFORMATION

© COPYRIGHT SUZUKI MOTOR CORPORATION 1995

1

2

3

4

5

6

7

8

SUPPLEMENTS

DR650SEV/W/X/Y

(’97/’98/’99/’00-MODELS)

9

DR650SEK1 (’01-MODEL)

10

DR650SEK2/K3/K4/K5/K6/K7

(’02/’03/’04/’05/’06/’ 07/’08-MODELS)

11

DR650SEK9 (’09-MODEL)

12

HOW TO USE THIS MANUAL

TO LOCATE WHAT YOU ARE

LOOKING FOR:

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

2. As the title of these sections are listed on the previous page as GROUP INDEX, select the section where what you are looking for belong.

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

4. On the first page of each section, its contents are listed. Find the item and page you need.

COMPONENT PARTS AND WORK TO BE DONE

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

Example: Front wheel

CD

O-ring

@ Housing end (inside)

@ Washer set

@ O-ring (2 pes)

®

Starter motor ease

®

Armature

(f) Washer set

®

Brush holder

®

Brush spring

®

Housing end (outside)

SYMBOL

Listed in the table below are the symbols indicating instructions and other information necessary for servicing and meaning associated with them respectively.

SYMBOL

1lr Apply oil. Use engine oil unless otherwise specified.

Apply SUZUKI SUPER GREASE ~

(99000-25030)

"12078]

• tJ

13

681

DEFINITION

~

Torque control required.

Data beside it indicates specified torque.

Apply SUZUKI SILICONE GREASE.

~

Apply SUZUKI MOLY PASTE.

~

Apply SUZUKI BOND" 1207B".

(99104-31140)

Apply THREAD LOCK" 1342".

(99000-32050)

Apply THREAD LOCK SUPER

"1360" .

(99000-32130)

DEFINITION SYMBOL

•

Apply THREAD LOCK SUPER

"1303" .

(99000-32030)

Use fork oil.

(99000-99044-10G) a

Apply or use brake fluid.

Measure in voltage range.

~

Measure in resistance range. ~

Measure in current range. ~

Use special tool.

'{ooli

1·1 GENERAL INFORMATION

WARNING/CAUTION/NOTE

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

A

WARNING

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

I

A CAUTION I

Indicates a potential hazard that could result in vehicle damage.

NOTE:

Indicates special information to make maintenance easier or instructions clearer.

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

GENERAL PRECAUTIONS

A

WARNING

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

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

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

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

• Never use gasoline as a cleaning solvent.

• To avoid getting burned, do not touch the engine, engine oil or exhaust system during or for a while after engine operation.

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

GENERAL INFORMATION 1·2

I

A. CAUTION I

• 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, and also lubricated when specified.

• When use of a certain type of lubricant, bond, or sealant is specified, be sure to use the specified type.

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

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

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

• Tighten cylinder head and case bolts and nuts, beginning with larger diameter and ending with smaller diameter, from inside to outside diagonally, to the specified tightening torque.

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

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

• Do not use self-locking nuts a few times over.

• Use a torque wrench to tighten fastners to the torque values when specified. Wipe off grease or oil if a thread is smeared with them.

• After reassembly, check parts for tightness and operation.

• To protect environment, do not unlawfully dispose of used motor oil and other fluids: batteries, and tires.

• To protect Earth's natural resouces, properly dispose of used vehicles and parts.

1·3 GENERAL INFORMATION

SUZUKI DR650SET ('96-MODEL)

RIGHT SIDE

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

LEFT SIDE

SERIAL NUMBER LOCATION

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

CD is stamped on the right side of the steering head pipe. The engine serial number @ is located on the left side of the crankcase.

These numbers are required especially for registering the machine and ordering spare parts.

FUEL AND OIL RECOMMENDATION

FUEL (For U.S.A. model)

1. Use only unleaded gasoline of at least 87 pump octane (R; M) method or 91 octane or higher rated by the research method.

2. Suzuki recommends that customers use alcohol free, unleaded gasoline whenever possible.

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

4. Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than

10% ethanol. Gasoline/alcohol fuel may contain up to 5% methanol if appropriate cosolvents and corrosion inhibitors are present in it.

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

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

FUEL (For Canadian model)

Use only unleaded gasoline of at least 87 pump octane (R

~

M) method or 91 octane or higher rated by the research method.

FUEL (For the other models)

Gasoline used should be graded 85-95 octane (Research Method) or higher. An unleaded gasoline type is recommended.

GENERAL INFORMATION 1·4

ENGINE OIL (For U.S.A. model)

SUZUKI recommends the use of SUZUKI PERFORMANCE

4 MOTOR OIL or an oil which is rated SE, SF or SG under the API (American Petroleum Institute) classification system.

The viscosity rating is SAE 10W/40. If an SAE 1 OW/40 motor oil is not available, select an alternate according to the right chart.

ENGINE OIL (For the other models)

Make sure that the engine oil you use comes under API classification of SE, SF or SG and that its viscosity rating is SAE

10W/40. If an SAE 1 OW/40 motor oil is not available, select an alternate according to the right chart.

BRAKE FLUID

Specification and classification: DOT 4

MUlTIGRADE

.

~.

.

.

10W 30

.

TEMP.

°C

OF -22 -4 14 32 50 68 86 104

AWARNING

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

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

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

FRONT FORK OIL

Use fork oil # 10

BREAK-IN PROCEDURES

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

• Keep to these break-in procedures:

Initial 800 km ( 500 miles): Less than 1/2 throttle

Up to 1 600 km (1 000 miles): Less than 3/4 throttle

• Upon reaching an odometer reading of 1 600 km (1 000 miles) you can subject the motorcycle to full throttle operation.

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

1-5 GENERAL INFORMATION

INFORMATION LABELS

1.0. plate

(For E-03, 28, 33)

Safety label

(For E-28)

Brake approval label (For E-02, 21, 22, 34, 53)

Regulation approval label

(For European markets)

Manufacturer plate

(For European markets)

LH VIEW RH VIEW

Engine starting label

Engine idle speed label

Right knuckle cover

Warning safety label

Starter motor

Fuel tank

LH VIEW

.~:I.-

-

Vacuum hose routing diagram label (For E-33)

1.0. label

GENERAL INFORMATION 1·6

Fuel tank

RH VIEW

Seat

Rear fender

Tire air pressure label

LH VIEW

Swingarm pivot

Swing arm

1-7 GENERAL INFORMATION

SPECIFICA TIONS

DIMENSIONS AND DRY MASS

Overall length ............................................. 2 345 mm (92.3 in) ..... E18, 22

2 325 mm (91.5 in) ..... E18, 22 (Low seat)

2 255 mm (88.8 in) ..... Others

2 235 mm (88.0 in) ..... Others (Low seat)

Overall width............................................. 865 mm (34.1 in)

Overall height ............................................. 1 205 mm (47.4 in)

1 165 mm (45.9 in) ..... (Low seat)

Wheelbase ................................................. 1 490 mm (58.7 in)

1 475 mm (58.1 in) ..... (Low seat)

Ground clearance........................................ 265 mm (10.4 in)

225 mm ( 8.9 in) ..... (Low seat)

Seat height ........... ................. .................... 885 mm (34.8 in)

845 mm (33 in) ..... (Low seat)

Dry mass................................................... 147 kg (324 Ibs)

ENGINE

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

Valve clearance (IN) .................................... 0.08-0.13 mm (0.003-0.005 in)

(EX) ................................... 0.17 -0.22 mm (0.007 -0.009 in)

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

Bore .......................................................... 100 mm (3.937 in)

Stroke ........... ..................................... ....... 82 mm (3.228 in)

Piston displacement .................................... 644 cm 3 (39.3 cu. in)

Compression ratio ....................................... 9.5 : 1

Carburetor ................................................. BST40, single

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

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

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

TRANSMISSION

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

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

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

Primary reduction ratio ................................ 2.178 (61/28)

Gear ratios, Low ......................................... 2.416 (29112)

2nd ......................................... 1.625 (26/16)

3rd .......................................... 1.238 (26121)

4th .......................................... 1.000 (21/21)

Top ......................................... 0.826 (19/23)

Final reduction ratio .................................... 2.800 (42115) ..... E03,28,33

2.733 (41115) ..... Others

Drive chain ................................................ 010525 V9, 110 links

GENERAL INFORMATION

1-8

CHASSIS

Rear suspension ......................................... Link type, coil spring, gas/oil damped, spring pre-load fully adjustable, compression damping force adjustable

Front fork stroke ........................................ 260 mm (10.2 in)

220 mm ( 8.7 in) ..... (Low seat)

Rear wheel travel ....................................... 260 mm (10.2 in)

220 mm ( 8.7 in) ..... (Low seat)

Steering angle ............................................ 43 0

Caster ....................................................... 28 0 30'

Trail .......................................................... 111 mm (4.37 in)

Turning radius ............................................ 2.5 m (8.2 ft)

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

Rear brake ................................................. Disc brake

Front tire size ............................................. 90/90-21 54S, tube type

Rear tire size .............................................. 120/90-17 64S, tube type

ELECTRICAL

Ignition type .............................................. Electronic ignition (COl)

Ignition timing ............................................ 10 0 B.T.D.C. at 1 500 rpm

Spark plug ................................................. NGK CR 1 OE or NIPPONDENSO U31 ESR-N

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

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

Fuse ......................................................... 30/10/1 OA

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

Parking or city light.. ................................... 12V 4W ..... except E03, 24, 28, 33

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

Tail/brake light ........................................... 12V 5/21 W

License plate light.. ..................................... 12V 5W

Speedometer light ....................................... 12V 3W

Neutral indicator light.. ................................ 12V 2W

High beam indicator light ............................. 12V 2W

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

CAPACITIES

Fuel tank, including reserve ......................... 12.0 L (3.2/2.6 US/Imp gal) ..... E33

13.0 L (3.4/2.9 US/Imp gal) ..... Others reserve .................... ........ ............ 3.0 L (0.8/0.7 US/Imp gal)

Engine oil, oil change .................................. 2 300 ml (2.4/2.0 US/Imp qt) with filter change ........................ 2400 ml (2.5/2.1 US/Imp qt) overhaul ..................................... 2 600 ml (2.7/2.3 US/Imp qt)

Front fork oil (each leg)............................... 565 ml (19.1119.9 US/Imp oz)

563 ml (19.0/19.8 US/Imp az) ..... (Low seat)

1-9 GENERAL INFORMATION

COUNTRY OR AREA

The series of symbols on the left stand for the countries or area on the right.

SYMBOL

E-22

E-24

E-25

E-28

E-33

E-34

E-37

E-39

E-53

E-02

E-03

E-04

E-15

E-16

E-17

E-18

E-21

COUNTRY or AREA

U.K.

U.S.A.

France

Finland

Norway

Sweden

Switzerland

Belgium

Germany

Australia

Netherlands

Canada

California (U.S.A.)

Italy

Brazil

Austria

Spain

(

E-1 5 and 16 countries are inc! uded in E-1 7.)

E-21 and 53 countries are included in E-34.

E-39 country is included in E-18.

2-1 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

IMPORTANT: The periodic maintenance intervals and service requirements have been established in accordance with EPA regulations. Following these instructions will ensure that the motorcycle will not exceed emission standards and it will also ensure the reliability and performance of the motorcycle.

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. Mileages are expressed in terms of kilometer, miles and time for your convenience.

NOTE:

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

PERIODIC MAINTENANCE CHART

INTERVAL:

THIS INTERVAL SHOULD BE JUDGED km miles

BY ODOMETER READING OR

MONTHS WHICHEVER COMES FIRST months

Valve clearance

Spark plugs

Air cleaner element

Carburetor idle rpm

Fuel line

(EVAP hose ... California model only)

Fuel valve strainer

Clutch

Engine oil

Engine oil filter

Drive chain

Brakes

Brake hose

Brake fluid

Tires

Spark arrester

Steering

Front forks

Rear suspension

Exhaust pipe and muffler bolts

Chassis bolts and nuts

1 000 6000 12 000 18000 24000

600 4000 7 500 11 000 15000

2 12 24 36 48

-

I -

I

I

R

-

I

I

R

-

R

R

I

Clean every 3 000 km (2 000 miles).

I I I I I

I I I I I

I

Replace every 4 years.

-

I

C

I

-

I

R R

-

I

R

R

I

-

I

R

I

C

I

R

Clean and lubricate every 1 000 km (600 miles).

I I I I I

I I I

Replace every 4 years.

I

I I I I

-

-

-

Change every 2 years.

I I I

Clean every 6 000 km (4 000 miles).

(For Canada and U.S.A.)

I I -

I

T

-

-

-

I

I

T -

-

-

I

I

I

T

T T T T T

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

R: Replace T: Tighten C: Clean

PERIODIC MAINTENANCE 2-2

LUBRICATION POINTS

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

Major lubrication points are indicated below.

I§'

Clutch lever holder - - - - - . and clutch cable and spring hook

i§'

Drive chain

I§'

Throttle cablp.--.......

NOTE:

* Lubricate exposed parts which are subject to rust, with a rust preventative spray whenever the motorcycle has been operated under wet or rainy conditions. If the spray is unavailable, use either motor oil or grease.

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

2·3 PERIODIC MAINTENANCE

MAINTENANCE AND TUNE-UP PROCEDURES

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

VALVE CLEARANCE

Inspect Initially at 1 000 km (600 miles, 2 months) and

Every 12 000 km (7 500 miles, 24 months) thereafter.

The valve clearance specification is different for intake and exhaust valves.

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

Valve clearance (when cold):

IN.: 0.08-0.13 mm (0.003-0.005 in)

EX.: 0.17 -0.22 mm (0.007 -0.009 in)

NOTE:

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

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

• Remove the frame covers, seat and fuel tank.

• Remove the spark plug and valve inspection caps, intake and exhaust.

• Remove the valve timing inspection plug and magneto cover cap.

• Turn the crankshaft counterclockwise with the box wrench to set the piston at T.D.C. on the compression stroke. (Turn the crankshaft until the "T" line

CD on the magneto rotor is aligned with the center of hole on the magneto cover.)

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

lim

09900-20803: Thickness gauge

09917 -14910: Valve clearance adjusting driver

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

• Securely tighten the lock nut after adjustment is completed.

I

A CAUTION

I

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

• Reinstall the spark plug, valve inspection caps, valve timing inspection plug and magneto cover cap.

SPARK PLUGS

Inspect Every 6 000 km (4000 miles, 12 months) and

Replace Every 12000 km (7 500 miles, 24 months).

• Remove the spark plugs. a

09930-101 21: Spark plug socket wrench set

-----

Standard Hot type

NGK

ND

CR10E

U31 ESR-N

CR9E

U27ESR-N

PERIODIC MAINTENANCE 2·4

CARBON DEPOSIT

Check to see the carbon deposit on the plug.

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

SPARK PLUG GAP

Measure the plug gap with a thickness gauge if it is correct.

If not, adjust it to the following gap.

Standard

Spark plug gap

0.7-0.8 mm

(0.028-0.031 in) a

09900-20803: Thickness gauge

ELECTRODE'S CONDITION

Check to see the worn or burnt condition of the electrodes.

If it is extremely worn or burnt, replace the plug. And also replace the plug if it has a broken insulator, damaged thread, etc.

I

A CAUTION I

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

\S=

I t

0.7-0.8 mm

(0.028-0.031 in)

2·5 PERIODIC MAINTENANCE

AIR CLEANER ELEMENT

I

Clean Every 3 000 km (2 000 miles).

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

Check and clean the element in the following manner.

• Remove the left frame cover.

• Remove the air cleaner case cover by removing screws

CD.

• Remove the air cleaner element by removing its support screw @.

• Remove the polyurethane foam element @ from the element frame @.

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

• Squeeze the cleaning solvent out of the washed element by pressing it between the palms of both hands.

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

NOTE:

Do not twist or wring the element because it will tear or the individual cells of the element will be damaged.

[ A

CAUTION [

Inspect the element carefully for rips, torn seams, etc.

If any damage is noted, replace the element.

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

• When installing the air cleaner element in the cleaner case, make sure that the flUP" mark comes upward.

[ A CAUTION [

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

NOTE:

When you clean the air cleaner element, drain water from the air cleaner drain hose by removing the drain plug.

Non-flammable

~ u:g

1 cleaning solvent

~

~.~

I' ".

~.-

[@

SAE

~OIL

PERIODIC MAINTENANCE 2-6

CARBURETOR

Inspect Initially at 1 000 km (600 miles, 2 months) and

Every 6 000 km (4 000 miles, 12 months) thereafter_

THROTTLE CABLE ADJUSTMENT

A twin throttle cable system is used in this motorcycle. Cable G) is for pulling and cable @ is for returning. To adjust the cable play, adjust the returning cable first and then adjust the pulling cable.

Returning cable play

The returning cable should be adjusted to have a thread length @of 3-4 mm (0.12-0.16 in) as shown in the Fig.

If the adjustment is necessary, adjust the thread length in the following way:

• Loosen the lock nuts @.

• Move the adjuster@ to obtain the thread length @of 3-4 mm (0.12-0.16 in).

• Tighten the lock nuts @ securely.

Pulling cable play

The pulling cable should be adjusted to have a cable play

® of 0.5-1.0 mm (0.02-0.04 in) as shown in the Fig. If the adjustment is necessary, adjust the cable play in the following way:

• Turn the handlebar all the way to the left.

• Loosen the lock nuts (@, @).

• Turn the adjuster

(j)

or move the adjuster

® to obtain the cable play @of 0.5-1.0 mm (0.02-0.04 in).

• Tighten the lock nuts (@, @) securely.

AWARNING

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

IDLE RPM ADJUSTMENT

NOTE:

Make this adjustment when the engine is warm.

• Connect a tachometer.

S

09900-26006: Tachometer

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

1 400 and 1 600 r/min by turning the throttle stop screw G).

• Turn in or out the pilot screw within 1/2 turn from the standard setting, and set it when the engine speed is at the highest possible level.

• After previous adjustment, recheck the idling speed and adjust to between 1 400 and 1 600 r/min with throttle stop screw if necessary.

Engine idle speed:

1 500 ± 50 r/min ... for Switzerland

1 500 ± 100 r/min ... for the Others

2·7 PERIODIC MAINTENANCE

FUEL LINE

(EVAP HOSE ... California model only)

Inspect Initially at 1 000 km (600 miles, 2 months) and

Every 6 000 km (4 000 miles, 12 months) thereafter.

Replace Every 4 years.

FUEL VALVE STRAINER

Clean Every 12 000 km (7 500 miles, 24 months).

Refer to page 4-2 for removal procedure.

CLUTCH

Inspect Initially at 1 000 km (600 miles, 2 months) and

Every 6 000 km (4 000 miles, 12 months) thereafter.

• Loosen the lock nut

CD and turn the clutch cable adjuster o fully in.

• Loosen the lock nut @ and turn the clutch cable adjuster

@ to provide the specified clutch lever play @.

Clutch lever play @: 10-15 mm (0.4-0.6 in)

• Tighten the lock nuts justers

(CD and @) while holding the ad-

(0 and @) in positions.

NOTE:

Minor adjustment can be made by the adjuster

0

after loosening the lock nut

CD.

At the same intervals, lubricate the clutch cable with motor oil

ENGINE OIL AND OIL FILTER

(ENGINE OIL)

Replace (Change) Initially at 1 000 km (600 miles, 2 months) and Every 6 000 km (4000 miles, 12 months) thereafter.

(OIL FILTER)

Replace Initially at 1 000 km (600 miles, 2 months) and

Every 12 000 km (7 500 miles, 24 months) thereafter.

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

• Keep the motorcycle upright, supported by jack or wooden block.

• Place an oil pan below the engine and remove the engine oil drain plug

CD and oil filler cap @ to drain engine oil.

• Remove the oil filter cap by removing the three bolts @.

• Remove the oil filter @ and install the new one.

• Install the oil filter cap and tighten the bolts @ securely.

NOTE:

Before installing the oil filter and oil filter cap, check to be sure that the spring

® and new O-rings r® and (j)) are installed correctly and apply engine oil lightly to the new Dring

®.

• Tighten the oil drain plug

CD securely, and pour fresh oil through the oil filler. The engine will hold about 2 300 ml of oil. Use an API classification of SE, SF or SG oil with

SAE 10W/40 viscosity.

~

Drain plug: 24 N·m (2.4 kg-m, 17.5 Ib-ft)

• Install the oil filler cap @.

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

• Turn off the engine and wait about one minute, then check the oil level through the inspection window

®.

If the level is below mark "F", add oil to the level.

NECESSARY AMOUNT OF ENGINE OIL

Oil change : 2 300 ml (2.4/2.0 US/Imp qt)

Filter change : 2 400 ml (2.5/2.1 US/Imp qt)

Overhaul engine: 2 600 ml (2.7/2.3 US/Imp qt)

PERIODIC MAINTENANCE 2·8

2·9 PERIODIC MAINTENANCE

DRIVE CHAIN

Inspect Initially at 1 000 km (600 miles, 2 months) and

Every 6 000 km (4 000 miles, 12 months) thereafter.

Clean and Lubricate Every 1 000 km (600 miles).

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

* Loose pins

* Damaged rollers

* Dry or rusted links

* Kinked or binding links

* Excessive wear

* Improper chain adjustment

* Missing O-ring seals

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

NOTE:

When rep/acing the drive chain, rep/ace the drive chain and sprockets as a set.

CHECKING

• Remove the axle cotter pin (Canada and U.S.A).

• Loosen the axle nut

CD .

• Tense the drive chain fully by turning both chain adjusters

0·

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

Drive chain 20-pitch length

Service Limit

319.4 mm

(12.6 in)

ADJUSTING

• Turn both chain adjusters

0 until the chain has 30-45 mm (1.2-1.8 in) of slack in the middle between engine and rear sprockets. The number on both chain adjusters must be at the same number on the scale to ensure that the front and rear wheels are correctly aligned.

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

• After adjusting the drive chain, tighten the axle nut

CD to the specified torque.

(with cotter pin)

Rear axle nut: 110 N·m (11.0 kg-m, 79.5Ib-ft)

(Self-locking)

CLEANING AND LUBRICATING

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

I

A CAUTION I

Do not use trichlene, gasoline or any similar fluids:

These fluids have too great a dissolving power for this chain and, what is more important, they can damage the "0" -rings (or seals) confining the grease in the bush to pin clearance_ Remember, high durability comes from the presence of grease in that clearance.

• After washing and drying the chain, oil it with a heavyweight motor oil.

I A CAUTION I

*

Do not use any oil sold commercially as "drive chain oil". Such oil can damage the "0" -rings (or seals).

*

The standard drive chain is D_LD. 525 V9, 110 links.

SUZUKI recommends that this standard drive chain should be used for the replacement.

BRAKES

(BRAKE)

Inspect Initially at 1 000 km (600 miles, 2 months) and

Every 6 000 km (4 000 miles, 12 months) thereafter.

(BRAKE HOSE AND BRAKE FLUID)

Inspect Every 6000 km (4 000 miles, 12 months). Replace hoses Every 4 years. Replace fluid Every 2 years.

BRAKE FLUID LEVEL

• Keep the motorcycle upright and place the handlebars straight.

• Check the brake fluid level by observing the lower limit lines on the front and rear brake fluid reservoirs.

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

III

Specification and Classification: DOT 4

AWARNING

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

AWARNING

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

PERIODIC MAINTENANCE 2-10

2-11 PERIODIC MAINTENANCE

BRAKE PADS

The extent of brake pad wear can be checked by observing the grooved limit line G) on the pad. When the wear exceeds the grooved limit line, replace the pads with new ones. (Refer to pages 5-7 and 5-34.)

I

A

CAUTION I

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

BRAKE PEDAL HEIGHT

• Loosen the lock nut @ and rotate the push rod @ to locate brake pedal 5 mm below the top face of the footrest.

• Retighten the lock nut @ to secure the push rod @ in the proper position.

Brake pedal height @: 5 mm (0.2 in)

AIR BLEEDING THE BRAKE FLUID CIRCUIT

Air trapped in the 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 up the master cylinder reservoir to the "UPPER" line.

Replace the reservoir cap to prevent entry of dirt.

• Attach a pipe to the caliper bleeder valve, and insert the free end of the pipe into a receptacle. t!J

Air bleeder valve: 8 N-m (0.8 kg-m, 6.0 Ib-ft)

• Front brake: Bleed the air from the air bleeder valve.

• Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it. Loosen the bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle; this will remove the tension of the brake lever causing it to touch the handlebar grip. Then, close the valve, pump and squeeze the lever, and open the valve. Repeat this process until the fluid flowing into the receptacle no longer contains air bubbles.

NOTE:

Replenish the brake fluid in the reservoir as necessary while bleeding the brake system. Make sure that there is always some fluid visible in the reservoir.

• Close the bleeder valve, and disconnect the pipe. Fill the reservoir with brake fluid to the "UPPER" end of the inspection window.

I

A

CAUTION

I

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

• The only difference between bleeding the front and rear brakes is that the rear master cylinder is actuated by a pedal.

TIRES

Inspect Every 6 000 km (4 000 miles, 12 months).

TIRE TREAD CONDITION

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

Tire tread depth limit: FRONT & REAR 3.0 mm (0.12 in)

PERIODIC MAINTENANCE 2·12

2·13 PERIODIC MAINTENANCE

TIRE PRESSURE

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

COLD INFLATION

TIRE PRESSURE

FRONT

REAR

SOLO RIDING DUAL RIDING kPa kg/cm2 psi kPa kg/cm2 psi

150 1.50 22 175 1.75 25

175 1.75 25 200 2.00 29

I

A CAUTION I

The standard tire fitted on this motorcycle is 90/90-21

54S for front and 120/90-17 64S for rear. The use of tires other than those specified may cause instability.

It is highly recommended to use a SUZUKI Genuine Tire.

SPARK ARRESTER (For U.S.A. and CANADA)

I

Clean Every 6 000 km (4 000 miles).

If the muffler is clogged with carbon particles, exhaust resistance will be increased with a resultant decrease in power output.

• Remove the drain plugs.

• Start the engine and rev it to blowout the accumulated carbon particles.

• Turn off the engine and wait until the muffler cools, then replace the drain plugs and tighten them securely.

STEERING

Inspect Initially at 1 000 km (600 miles, 2 months) and

Every 12000 km (7 500 miles, 24 months) thereafter.

Taper roller type bearings are used on the steering system for better handling. Steering should be adjusted properly for smooth turning of handlebars and safe running. Overtight steering prevents smooth turning of the handlebars and too loose steering will cause poor stability. Check that there is no play in the front fork assembly by supporting the machine so that the front wheel is off the ground, with the wheel straight ahead, grasp the lower fork tubes near the axle and pull forward. If play is found, perform steering bearing adjustment as described in page 5-20 of this manual.

FRONT FORKS

Inspect Every 12000 km (7 500 miles, 24 months).

Inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defective parts, if necessary. (Refer to page 5-14.)

REAR SUSPENSION

Inspect Every 12 000 km (7 500 miles, 24 months).

Inspect the rear shock absorber for oil leakage and check that there is no play in the swing arm assembly.

EXHAUST PIPE AND MUFFLER BOLTS

Tighten Initially at 1 000 km (600 miles, 2 months) and

Every 12 000 km (7 500 miles, 24 months) thereafter.

• Remove the right frame cover.

• Tighten the exhaust pipe bolts

CD, muffler connection bolt

@ and muffler bolts

® to the specified torque. t!J

Exhaust pipe bolt/Muffler connection bolt/

Muffler bolt: 26 N·m (2.6 kg-m, 19.0 Ib-ft)

PERIODIC MAINTENANCE 2·14

2·15

PERIODIC MAINTENANCE

CHASSIS BOLTS AND NUTS

Tighten Initially at 1 000 km (600 miles, 2 months) and

Every 6 000 km (4 000 miles, 12 months) thereafter.

Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-1 6 for the locations of the following nuts and bolts on the motorcycle.)

@

Item

CD

Steering stem head nut

Front fork upper clamp bolt

@ Front fork lower clamp bolt

@ Front fork cap bolt

®

Front axle

®

Front axle holder nut

(J)

Handlebars clamp bolt

®

Front brake master cylinder mounting bolt

®

Front brake caliper mounting bolt

@ Front brake caliper pad mounting bolt

®

Brake hose union bolt (Front & Rear)

@ Air bleeder valve (Front & Rear)

@ Brake disc bolt (Front & Rear)

@ Rear brake caliper pad mounting bolt

@ Rear brake master cylinder mounting bolt

@ Rear brake master cylinder rod lock nut

®

Front footrest bracket mounting bolt

@ Rear footrest bracket mounting bolt

@) Swingarm pivot nut

®

Rear shock absorber mounting bolt

(Upper & Lower)

®

Rear cushion lever/rod mounting nut

@ Rear cushion lever mounting bolt

@ Rear axle nut (with cotter pin)

®

Rear axle nut (Self-locking)

@ Rear sprocket nut/bolt

N·m

90

29

26

18

10

18

39

18

23

8

23

23

65

10

23

10

26

23

77

55

100

80

100

110

27

5.5

10.0

8.0

10.0

11.0

2.7

1.0

2.6

1.8

2.3

0.8

2.3

1.8

1.0

1.8

3.9

2.3

7.7 kg-m

9.0

2.9

2.6

2.3

6.5

1.0

2.3

40.0

72.5

58.0

72.5

79.5

19.5

16.5

7.0

19.0

13.0

16.5

6.0

16.5

Ib-ft

65.0

21.0

19.0

16.5

47.0

7.0

13.0

7.0

13.0

28.0

16.5

55.5

PERIODIC MAINTENANCE 2·16

2·17 PERIODIC MAINTENANCE

COMPRESSION PRESSURE CHECK

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

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

COMPRESSION PRESSURE SPECIFICATION

Standard

850 kPa

Approx. (8.5 kg /cm 2 )

120 psi

Low compression pressure can indicate any of the following conditions:

* Excessively worn cylinder wall

* Worn-down piston or piston rings

* Piston rings stuck in grooves

* Poor seating of valves

* Ruptured or otherwise defective cylinder head gasket

COMPRESSION TEST PROCEDURE

NOTE:

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

* Have the engine warmed up by idling before testing.

* Be sure that the battery used is in ful/y-charged condition.

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

• Remove the spark plug.

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

• Keep the throttle grip in full-open position.

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

09915-64510: Compression gauge

0991 5-6331 0: Adaptor

PERIODIC MAINTENANCE 2-18

OIL PRESSURE CHECK

Check periodically the oil pressure in the engine to judge roughly the condition of the moving parts.

OIL PRESSURE SPECIFICATION

Above 30 kPa (0.3 kg/cm2, 4.3 psi)

Below 70 kPa (0.7 kg/cm2, 10 psi) at 3 000 r/min., Oil temp. at 60°C (140°F)

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

LOW OIL PRESSURE

* Oil leakage from the oil passage way

* Damaged O-ring

* Defective oil pump

* Combination of above items

HIGH OIL PRESSURE

* Used a engine oil which is too high viscosity

* Clogged oil passage way

* Combination of above items

OIL PRESSURE TEST PROCEDURE

Check the oil pressure in the following manner.

• Remove the oil pressure inspection plug.

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

• Warm up the engine as follows:

Summer 10 min. at 2 000 r/min.

Winter 20 min. at 2 000 r/min.

• After warming up, increase the engine speed to 3 000 r/min. (with the engine tachometer), and read the oil pressure gauge.

_ 09915-74510: Oil pressure gauge

09900-26006: Tachometer

 

3-1 ENGINE

ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE

The parts listed below can be removed and reinstalled without removing the engine from the frame.

Refer to the page listed in each section for removal and reinstallation instructions.

ENGINE CENTER

Refet to page

Cam drive chain tensioner ................... 3- 9 and 57

Cylinder head cover ........................... 3-10 and 56

Camshaft/auto-decompression ............. 3-10 and 55

Cylinder head .................................... 3-10 and 54

Cylinder ............................................ 3-11 and 54

Piston ............................................... 3-11 and 53

Starter motor ..................................... 3-11 and 52

Cam drive chain ................................. 3-14 and 48

ENGINE LEFT SIDE

Refer to page

ENGINE RIGHT SIDE

Refer to page

Engine sprocket ...................... 3- 5 and 7 Clutch cover .......................... 3-13 and 50

Generator cover ..................... 3- 9 and 52 Clutch ................................... 3-13 and 49

Starter torque limiter ............... 3-11 and 52 Primary driven gear ................. 3-14 and 49

Starter idle gear ..................... 3-11 and 52 Primary drive gear .................. 3-14 and 48

Generator rotor ...................... 3-11 and 51 Oil pump driven gear ............... 3-14 and 48

Starter clutch ......................... 3-34 and 35 Oil pump assembly ................. 3-14 and 48

Starter gear ........................... 3-12 and 51 Neutral position indicator

Gearshift shaft ....................... 3-13 and 47 switch ................................... 3-14 and 47

Gearshift cam pawl and cam Oil filter ................................. 3-41 driven gear ............................ 3-13 and 46

ENGINE REMOVAL AND

REINSTALLATION

ENGINE REMOVAL

Before taking the engine out of the frame, thoroughly clean the engine with a suitable cleaner. The procedure of engine removal is sequentially explained in the following steps:

• Remove the oil drain plug

CD to drain out engine oil.

• Remove the frame covers. (Refer to page 5-1.)

• Remove the seat. (Refer to page 5-1.)

• Remove the battery holder plate @.

• Disconnect the battery

8 lead wire @ from the battery terminal.

• Remove the fuel tank. (Refer to page 4-3.)

• Remove the oil cooler hose mounting bolts.

• Remove the oil cooler holder with cooler by removing the mounting bolts.

ENGINE 3·2

3·3 ENGINE

• Remove the exhaust pipe bolts.

• Remove the exhaust pipe by loosening the connection bolt.

• Disconnect the pick-up coil/power source coil lead wire coupler

CD.

• Disconnect the generator coil and neutral position indicator switch lead wires.

• Disconnect the spark plug caps.

• Disconnect the throttle cables and starter (choke) cable.

• Disconnect the air vent hose.

• Remove the carburetor by loosening the mounting clamp screws.

• Disconnect the clutch cable by removing the cable lever.

• Disconnect the starter motor lead wire

CD and crankcase breather hose @.

• Remove the left front footrest @.

• Remove the engine sprocket cover @ and gearshift lever

®.

ENGINE 3·4

3-5 ENGINE

• Remove the engine sprocket bolts while depressing the rear brake pedal.

• Remove the engine sprocket.

NOTE:

If

it is difficult to remove the engine sprocket, loosen the rear axle nut and then adjust the chain adjusters to provide additional chain slack.

• Remove the engine ground wire and lead wire clamp.

• Remove the engine mounting nuts, bolts, spacers and brackets.

• Remove the engine through the left side of the frame.

ENGINE

3·6

ENGINE REINSTALLATION

Reinstall the engine in the reverse order of engine removal.

• Insert the two long bolts from left side. Install the brackets, spacers, bolts and nuts properly, as shown in the following illustration.

NOTE:

The engine mounting nuts are self-locking. Once the nut has been removed, it is no longer of any use.

Be sure to use new nuts and tighten them to the specified torque.

'hl---CD

®

--

ITEM

@

@©@®

®@

~

@

.®.e--, @~~

©

~~

~

I

@

N'm

40

65

40

23 kg-m

4.0

6.5

4.0

2.3

Ib-ft

29.0

47.0

29.0

16.5

LENGTH

Bolt

CD

Bolt@

53 mm (2.1 in)

100 mm (3.9 in)

235 mm (9.3 in) Bolt@

Bolt @) 235 mm (9.3 in)

Bolt

® 130mm(5.1in)

Spacer

® 27 mm (1.1 in)

Spacer

(J)

65 mm (2.6 in)

3·7 ENGINE

• Apply THREAD LOCK SUPER" 1303" to the engine sprocket mounting bolts and tighten them to the specified torque.

• Install the oil cooler hoses to the clutch cover and cylinder head correctly.

I

A CAUTION I

Replace the O-rings

CD with new one to prevent oil leakage.

• Tighten the oil cooler hose securing bolts to the specified torque.

• Tighten the front footrest bolts to the specified torque.

• After remounting the engine, route the wiring harnesses, cables and hoses properly by referring to the sections, for wire routing, cable routing and hose routing. (Refer to pages 7-12 through 7-18.)

• Adjust the following items to the specification.

* Throttle cable play ................. (Refer to page 2-6.)

* Idling adjustment ................... (Refer to page 2-6.)

* Clutch cable play ................... (Refer to page 2-7.)

* Drive chain slack .................... (Refer to page 2-9.)

• Pour 2.6 L (2.7/2.3 US/Imp qt) of engine oil SAE 10W/40 graded SE, SF or SG into the engine after overhauling engine.

* Start up the engine and allow it run for several minutes at idle speed. About five minutes after stopping engine, check oil level.

If the level is below the "F" mark, add oil until the level reaches the "F" mark.

Change

Filter change

Overhaul

2 300 ml (2.4/2.0 US/Imp qt)

2 400 ml (2.5/2.1 US/Imp qt)

2 600 ml (2.7/2.3 US/Imp qt)

ENGINE 3·8

3·9 ENGINE

ENGINE DISASSEMBLY

• Remove the oil pipe by removing the mounting bolts.

• Remove the cam drive chain tensioner by removing the bolts.

• Remove the two spark plugs.

• Remove the generator cover by removing the bolts.

NOTE:

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

Align "TOP" line

CD

on the generator rotor with index mark

@

on the crankcase.

• Remove the valve inspection caps (Intake and Exhaust) by removing the bolts.

• Loosen the cylinder head cover bolts in the ascending order numbers and remove the cylinder head cover.

• Flatten the lock washer and remove the camshaft sprocket bolts.

• Remove the sprocket and camshaft/auto-decompression assembly.

NOTE:

The cam chain tensioner bolt

CD is to be removed only when disassembling the engine.

I

A. CAUTION

I

Do not drop camshaft drive chain, pin, C-ring or sprocket into the crankcase.

• Remove the cylinder head by removing the bolts and nuts diagonally.

NOTE:

If it is difficult to remove the cylinder head, gently pry it off while tapping the finless portion of the cylinder head with a plastic hammer. Be careful not to break the fins.

ENGINE 3-10

3·11 ENGINE

• Remove the cylinder by removing the nuts.

I

A

CAUTION I

If tapping with a plastic hammer is necessary, do not break the fins.

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

• Remove the piston by removing the piston pin.

• Remove the clutch cable holder and starter motor.

• Remove the starter torque limiter

CD and starter idle gear

@ with shaft.

• Loosen the generator rotor bolt with the 36 mm offset wrench.

NOTE:

Do not remove the generator rotor bolt after loosening the bolt. The generator rotor bolt is used in conjunction with the rotor remover, when removing the generator rotor.

• Remove the generator rotor with the special tool. lim

09930-33720: Rotor remover

• Remove the key

CD.

• Remove the starter gear @.

• Remove the thrust washer @.

• Remove the ring nut with the special tools, then remove the spacer.

S

09917-23711: Ring nut socket wrench

09910-20116: Conrod holder

• Remove the crankcase oil separator @ by removing the screws.

• Remove the spacer @.

• Remove the gearshift cover by removing the bolts.

ENGINE 3·12

3·13 ENGINE

• Extract the gearshift shaft G) and remove the cam driven gear @ by removing the screws @.

NOTE:

When removing the cam driven gear, do not lose gearshift pawl@, pin

® and spring

®.

• Remove the clutch cover by removing the bolts.

• Remove the clutch pressure plate by removing the bolts diagonally.

• Remove the clutch drive and driven plates.

• Flatten the lock washer and remove the clutch sleeve hub nut with the special tool.

• Remove the thrust washer G) and primary driven gear assembly.

• Remove the thrust washer @.

• Remove the primary drive gear nut with the special tool. a

09910-20116: Conrod holder

I

A CAUTION I

I

This nut has left-hand thread nut.

• Remove the cam drive chain @ and key @.

• Remove the idle gear and oil pump driven gear by removing the circlips. a

09900-06107: Snap ring pliers

• Remove the oil pump by removing the mounting screws.

• Remove the breather cover.

• Remove the neutral position indicator switch.

NOTE:

Do not loose the switch contact

®

and spring

®.

ENGINE 3·14

3·15 ENGINE

• Remove the crancase securing bolts.

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

•

09920-13120: Crankcase separating tool

09910-33210: Crankshaft installer attachment

NOTE:

Fit the crankcase separating tool, so that the tool plate is parallel with the end face of the crankcase.

I

A. CAUTION I

The crankshaft and transmission components must remain in the right crankcase half. This is necessary because the gearshift cam stopper is mounted on the right crankcase half and will be damaged if the transmission components remain in the left half.

• Remove the gearshift cam stopper.

• Remove the gearshift fork shafts and gearshift forks.

• Remove the gearshift cam.

• Remove the driveshaft assembly and countershaft assembly_

• Align the punched marks on the balancer drive gear and driven gear.

• Remove the balancershaft assembly.

• Remove the crankshaft from the crankcase by using a crankshaft remover. a

09920-13120: Crankshaft remover

(Crankcase separating tool)

• Remove the oil sump filter cover

CD by removing the bolts.

• Remove the oil sump filter @.

ENGINE 3-16

3·17

ENGINE

ENGINE COMPONENTS INSPECTION AND SERVICE

CYLINDER HEAD COVER SERVICE

I

A CAUTION I

Be sure to identify each removed part as to its location, and lay the parts out in groups designated as "Exhaust", "Inlet", so that each will be restored to the original location during assembly.

• Remove the intake and exhaust rocker arm shaft set bolts.

• Remove the intake and exhaust rocker arm shafts with a 6 mm bolt.

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.

Service Limit: 0.05 mm (0.002 in)

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

ROCKER ARM SHAFT

O.D.

Measure the diameter of rocker arm shaft with a micrometer.

Standard: 11.973-11.984 mm (O.4714-0.4718 in)

_ 09900-20205: Micrometer (O-25 mm)

ROCKER ARM

I.D.

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

Standard: 12.000-12.018 mm (0.4724-0.4731 in)

_ 09900-20605: Dial calipers

ROCKER ARM AND SHAFT REASSEMBLY

• Apply SUZUKI MOLY PASTE to the rocker arm shafts.

~99000-25140:

SUZUKI MOLY PASTE

• Install the rocker arms and shafts as shown in the illustration.

• Tighten the rocker arm shaft set bolts

CD to the specified torque.

[!J

Set bolt

CD:

28 N·m (2.8 kg-m, 20.0 Ib-ft)

NOTE:

Use new gasket on the set bolts

CD.

ENGINE 3·18

3-19 ENGINE

CYLINDER HEAD SERVICE

• Remove the cam chain tensioner by removing the bolt.

• Compress the springs with the special tools.

• Remove the valve cotters from the valve stem. a

09916-14510: Valve spring compressor

09916-14910: Valve spring compressor attachment

09916-84511: Tweezers

• Remove the valve spring retainer, inner spring and outer spring.

• Remove the vlave stem from the other side.

• Remove the oil seal with a long-nose pliers.

• Remove the spring seat.

NOTE:

Removal of the valves completes ordinary disassembling work. If valve guides have to be removed for replacement after inspecting related parts, carry out the steps shown in valve guide servicing.

CYLINDER HEAD DISTORTION

Decarbonize the combustion chamber.

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

Service Limit: 0.05 mm (0.002 in)

VALVE FACE WEAR

Measure the thickness

CD and, if the thickness is found to have been reduced to the limit, replace the valve.

NOTE:

Visually inspect each valve for wear of its seating face.

Replace any valve with an abnormally worn face.

Service Limit: 0.5 mm (0.02 in)

VALVE STEM RUNOUT

Support the valve with "V" blocks, as shown, and check its runout with a dial gauge. The valve must be replaced if the runout exceeds the limit.

Service Limit: 0.05 mm (0.002 in)

_ 09900-20701: Megnetic stand

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

09900-21304: V-block (100 mm)

VALVE HEAD RADIAL RUNOUT

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

If it measures more than limit, replace the valve.

Service Limit: 0.03 mm (0.001 in)

VALVE STEM DEFLECTION

Lift the valve about 10 mm (0.39 in) from the valve seat.

Measure the deflection in two directions, "X" and "Y" perpendicular to each other, by positioning the dial gauge as shown. If the deflection measured exceeds the limit specified below, then determine whether the valve or the guide should be replaced with a new one.

,g1l

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

09900-20701: Magnetic stand

Service Limit

Intake and exhaust valves: 0.35 mm (0.014 in)

ENGINE 3-20

3·21

ENGINE

VALVE STEM WEAR

If the valve stem is worn down to the limit, when measured with a micrometer, where the clearance is found to be in excess of the limit indicated, replace the valve; if the stem is within the limit, then replace the guide. After replacing valve or guide, be sure to recheck the clearance.

Standard

IN. : 5.475-5.490 mm (0.2156-0.2161 in)

EX.: 5.455-5.470 mm (0.2148-0.2154 in)

VALVE GUIDE SERVICING

• Remove the valve guide toward the camshaft side with the valve guide remover.

NOTE:

* Discard the removed valve guide subassemblies.

* Only oversized valve guides are available as replacement part. (Part No. 11115-32E70.)

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

CD and handle @.

,gOlf

09916-34580: Valve guide reamer

09916-34541: Reamer handle

• Fit a ring to each vi ave guide. Be sure to use new rings and valve guides.

• Oil the stem hole, too, of each valve guide and drive the guide into the guide hole with the valve guide installer. lim

09916-44910: Valve guide remover/installer

I

A

CAUTION I

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

• After fitting the valve guides, re-finish their guiding bores with the reamer @ and handle @. Be sure to clean and oil the guides after reaming. lim

09916-34550: Valve guide reamer

09916-34541: Reamer handle

VALVE SEAT WIDTH

• Coat the valve seat uniformly with Prussian blue. Fit the valve and tap the coated seat with the valve face in a rotating manner, in order to obtain a clear impression of the seating contact. In this operation, use the valve lapper to hold the valve head.

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

Standard

Valve seat width @: 0.9-1.1 mm (0.035-0.043 in)

If either requirement is not met, correct the seat by servicing it as follows.

VALVE SEAT SERVICING

The valve seats for both intake and exhaust valves are machined to two different angles. (The seat contact surface is cut 45°.) ----

INTAKE EXHAUST

45°

15°

N-615

N-615

N-615

N-121

(For U.S.A.)

Valve seat cutter (N-615)

Valve seat cutter (N-121)

Solid pilot (N-140-7.0)

(For the Others)

S

09916-24900: Valve seat cutter set

09916-20610: Valve seat cutter (N-121)

09916-24210: Valve seat cutter (N-615)

(N-140-7.0) : Solid pilot

NOTE:

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

• Insert the solid pilot with a slight rotation, seat the pilot snugly. Install the 45° cutter and T-handle.

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

• Inspect the seat by the previously described seat width measurement procedure. If the seat is pitted or burned, additional seat conditioning with the 45 ° cutter is required.

NOTE:

Cut 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.

ENGINE 3-22

3·23 ENGINE

If the contact area is too high on the valve, or if it is too wide, use the 15 0 cutter to lower and narrow the contact area.

Contact area too high and too wide on face of valve

If the contact area is too low or too narrow, use the 45

0 cutter to raise and widen the contact area.

Contact area too low and too narrow on face of valve

• After the desired seat position and width is achieved, use the 45 0 cutter very lightly to clean up and burrs caused by the previous cutting operations.

] ACAUTION]

DO NOT use lapping compound after the final cut is made. The finished valve seat should have a velvety smooth finish and not a highly polished or shiny finish.

This will provide a soft surface for the final seating of the valve which will occur during the first few seconds of engine operation.

• Clean and assemble the head and valve components. Fill the intake and exhaust ports with gasoline to check for leaks. If any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from sealing.

A WARNING

Always use extreme caution when handling gasoline.

NOTE:

After servicing the valve seats, be sure to check the valve clearance after the cylinder head has been reinstalled. (Refer to page 2-3.)

VALVE STEM END CONDITION

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

CD will not be reduced to less than 2.7 mm (0.11 in). If this length becomes less than 2.7 mm (0.11 in), the valve should be replaced. After installing a valve whose stem end has been ground off as above, check to ensure that the face @ of the valve stem end is above the cotters @.

VALVE SPRING

The force of the coil spring keeps the valve seat tight.

Weakened spring result in reduced engine power output, and often account for the chattering noise coming from the valve mechanism.

Check the springs for proper strength by measuring their free length and also by the force required to compress them.

If the spring length is less than the service limit, or if the force required to compress the spring does not fall within the range specified, replace both inner and outer springs as a set.

S

09900-20102: Vernier calipers

Valve spring free length

Service Limit

INNER : 34.4 mm (1.35 in)

OUTER: 38.1 mm (1.50 in)

Valve spring tension

Standard

INNER: 5.9-6.7 kg/27.5 mm (13.0-14.8Ibs/1.1 in)

OUTER: 13.8-15.8 kg/31.0 mm (30.4-34.8 Ibs/1.2 in)

VALVE AND VALVE SPRING REASSEMBLY

• Install the valve spring seat

CD.

Be careful not to confuse the lower seat with the spring retainer @.

5.9-6.7 kg

.!}

ENGINE 3·24

• Lubricate each seal with oil, and fit the seals onto each guide.

I

A

CAUTION I

I

Do not reuse the oil seals.

3·25 ENGINE

• Insert the valves, with their stems coated with (SUZUKI

MOLY PASTE) all around and along the full stem length without any break.

Similarly oil the lip of the stem seal.

~99000-25140:

SUZUKI MOLY PASTE

I

A CAUTION I

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

• Install the valve springs, making sure that the close-pitch end

CD of each spring goes in first to rest on the head.

The coil pitch of both inner and outer springs vary: the pitch decreases from top to bottom, as shown in the illustration.

~.

~ e

'J.

)

~

------r

I

~ ~ ~CD

Towards

~i ~

Head

• Put on the valve spring retainer, and using the valve lifter, press down the springs, fit the cotter halves to the stem end, and release the lifter to allow the cotter @ to wedge in between retainer and stem. Be sure that the rounded lip @ of the cotter fits snugly into the groove @ in the stem end.

ItitI

09916-14510: Valve spring compressor

09916-14910: Valve spring compressor attachment

09916-84511: Tweezers

I

A CAUTION I

Be sure to locate each spring and valve to their original positions.

CAMSHAFT/AUTOMATIC DE-COMP.

ASSEMBLY

I

A CAUTION I

Do not attempt to disassemble the camshaft/automatic de-compo assembly. It is not serviceable.

AUTOMATIC DE-COMP.

Move the automatic de-comp_ weight by hand to inspect if operating smoothly.

If it does not smoothly must be replaced with a new camshaft/automatic de-compo assembly.

CAMSHAFT

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

CAMSHAFT CAM WEAR

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

The limit of cam wear is specified for both intake and exhaust cams in terms of cam height 6), which is to be measured with micrometer.

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

• fcFob

09900-20202: Micrometer (25-50 mm)

Cam height 6)

Service Limit

Intake cam : 33.410 mm (1.3154 in)

Exhaust cam: 33.400 mm (1.3150 in)

CAMSHAFT JOURNAL WEAR

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

Camshaft journal oil clearance

Service Limit: 0.150 mm (0.0059 in)

• Tighten the cylinder head cover bolts evenly and diagonally to the specified torque.

10 N'm (1.0 kg-m, 7.0 Ib-ft) lim

09900-22301: Plastigauge

NOTE:

To properly measure the oil clearance with plasti-gauge, all gasket material must be removed from fitting surfaces of cylinder head and cover. Do not apply SUZUKI BOND

No. 1207B until after the oil clearance has been determined.

ENGINE

3-26

3·27 ENGINE

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

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

11m

09900-20205: Micrometer (0-25 mm)

Camshaft journal O.D.: 21.959-21.980 mm

(Right & Center) (0.8645-0.8654 in)

Camshaft journal O. D.: 17.466 -17.484 mm

(Left) (0.6877 -0.6883 in)

CAMSHAFT RUNOUT

Measure the runout with a dial gauge. Replace the camshaft if the runout exceeds the limit.

Service Limit: 0.10 mm (0.004 in)

11m

09900-20701: Magnetic stand

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

09900-21304: V-block

CYLINDER DISTORTION

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

Service Limit: 0.05 mm (0.002 in)

CYLINDER BORE

Inspect the cylinder wall for nicks, scratches or other damage.

11m

09900-20508: Cylinder bore gauge set

09900-20513: Gauge rod

Standard: 100.000-100.015 mm (3.9370-3.9376 in)

PISTON DIAMETER

Using a micrometer, measure the piston outside diameter at the place 21 mm (0.8 in) from the skirt end as shown in Fig. If the measurement is less than the limit, replace the piston.

11m

09900-20204: Micrometer (75-100 mm)

Service Limit: 99.880 mm (3.9323 in)

21 mm

~

PISTON -CYLINDER CLEARANCE

As a result of the previous measurement, if the piston to cylinder clearance exceeds the limit, replace both cylinder and piston.

Service Limit: 0.120 mm (0.0047 in)

PISTON RING-GROOVE CLEARANCE

Using a thickness gauge, measure the side clearance of the

1 st and 2nd rings. If any of the clearances exceeds the limit, replace both piston and piston rings.

em

09900-20803: Thickness gauge

09900-20205: Micrometer (0-25 mm)

Piston ring-groove clearance

Service Limit

1 st : 0.180 mm (0.0071 in)

2nd: 0.150 mm (0.0059 in)

Piston ring groove width

Standard

1st: 1.23-1.25 mm (0.048-0.049 in)

2nd: 1.21-1.23 mm (0.047-0.048 in)

Oil : 2.81-2.83 mm (0.110-0.111 in)

Piston ring thickness

Standard

1 st : 1.170-1.190 mm (0.0461-0.469 in)

2nd: 1.150-1.170 mm (0.0453-0.0461 in)

NOTE:

Using a soft-metal scraper, decarbon the crown of the piston. Clean the ring grooves similar/y.

PISTON RING FREE END GAP AND

PISTON RING END GAP

Before installing piston rings, measure the free end gap of each ring using vernier calipers.

Next, fit the ring in the cylinder, and measure each ring end gap using a thickness gauge.

If any ring has an excess end gap, replace the ring.

lib

09900-20102: Vernier calipers

Piston ring free end gap

Service Limit

1st: 10.8 mm (0.43 in)

2nd: 9.1 mm (0.36 in)

lib

09900-20803: Thickness gauge

Piston ring end gap

Service Limit

1 st: 0.50 mm (0.020 in)

2nd: 1.00 mm (0.039 in)

ENGINE 3·28

3·29 ENGINE

PISTON PIN AND PIN BORE

Using a caliper gauge, measure the piston pin bore inside diameter, and using a micrometer measure the piston pin outside diameter. If the difference between these two measurements is more than the limits, replace both piston and piston pin. em

09900-20605: Dial calipers

09900-20205: Micrometer (0-25 mm)

Piston pin bore

Service Limit: 23.030 mm (0.9067 in)

Piston pin 0.0.

Service Limit: 22.980 mm (0.9047 in)

CONROD SMALL END I.D.

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

,molt

09900-20605: Dial calipers

Service Limit: 23.040 mm (0.9071 in)

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

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.

,M;lt

09900-20701: Magnetic stand

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

09900-21304 : V-block

Service Limit: 3.0 mm (0.12 in)

Push the big end of the conrod to one side and measure the side clearance with a thickness gauge_

,roOl,

09900-20803: Thickness gauge

Service Limit: 1_00 mm (0_039 in)

Where the limit is exceeded, replace crankshaft assembly or reduce the deflection and the side clearance to within the limit by replacing the worn parts-conrod, big end bearing and crank pin etc.

CRANKSHAFT RUNOUT

Support the crankshaft with "V" blocks as shown, with the two end journals resting on the blocks.

Position the dial gauge, as shown, and rotate the crankshaft slowly to read the runout.

Correct or replace the crankshaft if the runout is greater than the limit.

'@u

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

09900-20701: Magnetic stand

09900-21304: V-block (100 mm)

Service Limit: 0.05 mm (0.002 in)

ENGINE 3-30

3·31 ENGINE

BALANCERSHAFT AND GEAR

G) Balaneershaft

@Key

@ Inner raee

@ Spring (6 pes)

®

Pin (3 pes)

®

Driven gear

(}) Washer

®

Washer

®

Circiip

DISASSEMBL Y

• Remove the circlip G) and washers (@, @).

• Remove the balancer driven gear.

• Remove the 6 springs and 3 pins.

Inspect the crank balancershaft wear or damage.

ENGINE 3-32

REASSEMBLY

• When installing the inner race, align the pin with groove of inner race.

• When installing the balancer driven gear, align the two punched marks as shown in photo.

• When installing the 6 springs

CD and 3 pins @, set the pins @ to the triangle position as shown in photo.

CLUTCH DRIVE PLATE

Measure the thickness of each drive plate with vernier calipers. Replace drive plates found to have worn down to the limit.

Iii1

09900-20102: Vernier calipers

Standard

Thickness No.1 & No.2: 2.9-3_1 mm (0.11-0_12 in)

Service Limit

Thickness No.1 & No.2: 2.6 mm (0.10 in)

Measuring thickness

3·33 ENGINE

CLUTCH DRIVEN PLATE

Measure each driven plate for distortion with a thickness gauge. Replace driven plates which exceed the limit.

S

09900-20803: Thickness gauge

Service Limit: 0.1 mm (0.004 in)

Measuring distortion

CLUTCH SPRING FREE LENGTH

Measure the free length of each coil spring with a vernier calipers, and determine the elastic strength of each. Replace any spring not within the limit.

S

09900-20102: Vernier calipers

Service Limit: 33.0 mm (1.30 in)

CLUTCH RELEASE BEARING

Inspect the release bearing for any abnormality, particularly cracks, to decide whether it can be reused or should be replaced. Smooth engagement and disengagement of the clutch depends much on the condition of this bearing.

CLUTCH RELEASE PINION AND RACK

Rotate the clutch release pinion by hand to inspect for a smooth roration. If a large resistance is felt to rotation, inspect the pinion and rack for damage or wear. If the defect is found, replace them as a set.

Measuring clutch spring

STARTER CLUTCH

CD

Starter clutch

@ Bearing

@ Starter idle gear

@ Idle gear shaft

®

Starter torque limiter

®

ENGINE 3-34

N'm

25 kg-m

2.5

Ib-ft

18.0

DISASSEMBL Y

• Remove the starter clutch gear.

• Remove the 3 bolts with a 6 mm hexagon wrench and

36 mm offset wrench.

3·35 ENGINE

STARTER CLUTCH

Inspcet the stater clutch wear or damage.

REASSEMBLY

• Apply THREAD LOCK SUPER

"1303"

to the bolts and tighten them to the specified torque .

.tJa

99000-32030: THREAD LOCK SUPER

"1303"

~Bolt:

25 N'm (2.5 kg-m, 18.0 Ib-ft)

Check that the rotor

CD turns in the direction of the arrow mark @ on the rotor while holding the starter gear, and that the rotor never turns in the opposite direction of the arrow mark.

STARTER TORQUE LIMITER

[ A CAUTION [

Do not attempt to disassemble the starter toque limiter.

It is not serviceable.

Check the slip torque with the special tools.

Slip torque: 42-64 N'm (4.2-6.4 kg-m, 30.5-46.5Ib-ft)

.MOlt

09930-73110: Starter torque limiter holder

09930-73120: Starter torque limiter socket

Set the starter torque limiter to the special tools and vise as shown in the photograph.

If the slip torque is not within the specification, replace the starter torque limiter with a new one.

TRANSMISSION

• Disassemble the transmission gears as shown in the illustration.

ENGINE 3-36

CD

Low driven gear

@ Top driven gear

@ 3rd driven gear

@ 4th driven gear

®

2nd driven gear

®

Driveshaft

(j) Countershaft/Low drive gear

®

Top drive gear

®

3rd drive gear

@ 4th drive gear

@ 2nd drive gear

2ND DRIVE GEAR DISASSEMBLY

• Remove the 2nd drive gear by using the gear puller and appropriate attachment .

• gob

09913-60910: Gear puller

3·37 ENGINE

SHIFT FORK-GROOVE CLEARANCE

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

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

Shift fork-Groove clearance

Standard: 0.10-0.30 mm (0.004-0.012 in)

Service Limit: 0.50 mm (0.020 in)

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

ItitI

09900-20803: Thickness gauge

09900-20102: Vernier calipers

Shift fork groove width

Standard: 5.0-5.1 mm (0.197 -0.200 in)

Checking clearance

Checking groove width

Shift fork thickness

Standard: 4.8-4.9 mm (0.189-0.193 in)

Checking thickness

REASSEMBLY

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

NOTE:

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

~99000-25140:

SUZUKI MOLY PASTE

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

I A CAUTION I

*

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

*

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

*

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

2ND DRIVE GEAR

• Press-fit 2nd drive gear

CD onto the countershaft.

NOTE:

Before reassembling, coat the internal face of the 2nd drive gear with THREAD LOCK SUPER "1303".

-Q

99000-32030: THREAD LOCK SUPER

"1303"

NOTE:

Take care not to smear 4th drive gear with THREAD LOCK

SUPER "1303".

NOTE:

* After mounting the 2nd drive gear, check that 4th drive gear spins smoothly by moving it with your fingers.

* This procedure may be performed only twice before shaft replacement is required.

3RD DRIVEN GEAR BUSHING

• When installing the gear bushing onto the drives haft, align the oil hole @ of the shaft with the bushing oil hole @.

rI""

Sharp edge

ENGINE 3·38

3-39 ENGINE

NOTE:

In reassembling the transmission, attention must be given to the locations and positions of washers and eirclips. The cross sectional view given here will serve as a reference for correctly mounting the gears, washers and eire/ips.

ENGINE 3·40

OIL NOZZLE AND OIL JET

REMOVAL

• Remove the oil nozzle

CD and oil jet @ of the right crankcase.

I

A

CAUTION I

The removed oil jet @ should be replaced with a new one.

INSPECTION

Check the oil nozzle for any damage or clogging.

REASSEMBLY

• Install the new oil jet @ as shown in the illustration.

• Install the oil nozzle

CD.

• Apply THREAD LOCK SUPER "1303" to the bolt and tighten to the specified torque.

"1303"

~

10 N·m (1.0 kg-m, 7.0 Ib-ft)

CRANKCASE BEARINGS

Inspect the play of the crankcase bearings by hand while they are in the left and right crankcase. Rotate each crankcase bearing inner race by hand to inspect for abnormal noise and smooth rotation. Replace the bearing if there is anything unusual.

NOTE:

When reassembling the bearing retainer @, apply a small quantity of THREAD LOCK "1342" to the bearing retainer screws and bolts.

Play

Play

3-41 ENGINE

OIL FILTER

• Remove the oil filter cap_

• Remove the oil filter 0)_

• Install the new oil filter.

NOTE:

Before installing the oil filter and oil filter cap, check to be sure that the spring @ and new a-rings (@ and @) are installed correctly_

GENERATOR

• Remove the generator coil_

• Remove the bearing by removing the circlip_

ENGINE REASSEMBLY

The engine is reassembled by carrying out the steps of disassembly in the reverse order, but there are a number of steps that demand special descriptions or precautionary measures.

NOTE:

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

OIL SEALS

• Fit the respective oil seals to the crankcase, clutch cover and gearshift cover.

• Apply SUZUKI SUPER GREASE

I f

A" to the lip of oil seals.

~99000-32030:

SUZUKI SUPER GREASE "A"

! ACAUTION!

Replace the oil seals with new ones every disassembly to prevent oil leakage.

ENGINE 3·42

3·43 ENGINE

CRANKSHAFT

CD

Crankshaft (R)

@ Conrod

@ Crank pin

@ Crankshaft (L)

®

Crankshaft bearing nut

®

Balancer drive gear o

Primary drive gear

CD

®

!"~

~4

['0 ' @

®

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

STD width between webs: 71.0 ± 0.1 mm

(2.795 ± 0.004 in)

®

®

@

N·m

80

100 kg·m

8.0

10.0

Ib-ft

58.0

72.5

• When mounting the crankshaft in the crankcase, it is necessary to pull its right end into the crankcase. em

09910-32812: Crankshaft installer

09910-32830: Attachment

09910-32860: Attachment

I

A CAUTION I

Never fit the crankshaft into the crankcase by striking it with a plastic hammer.

Always use the special tool, otherwise crankshaft alignment accuracy will be affected.

71.0±O.1 mm

I

(2.795±O.004 in)--1 am

BALANCERSHAFT

• When installing the balancershaft, align the punched marks (CD, @) on the balancer drive gear and driven gear.

GEARSHIFT MECHANISM

®

CD

,~~ if

~

®

ENGINE 3-44

CD

Gearshift arm stopper

@ Gearshift shaft

@ Gearshift lever

@ Cam stopper plate

®

Cam stopper

®

Cam stopper bolt o

Gearshift cam

®

Gearshift fork No.1

®

Gearshift fork No.2

@ Gearshift fork No.3

@ Pawl lifter

@ Cam guide

@ Cam driven gear kg-m

1.9

Ib-ft

13.5

3·45

ENGINE

• After installing the countershaft assembly and driveshaft assembly into the right crankcase, fit the gearshift forks

CD, @ and @ into the gearshift fork grooves.

CD

For Top driven gear (No.1)

@ For 4th driven gear (No.2)

@ For 3rd drive gear (No.3)

NOTE:

Three kinds of gearshift forks,

CD, @ and@ are used. They resemble each other very closely in external appearance and configuration.

Carefully examine the illustration for correct installing positions and directions.

• Position the gearshift cam as shown in photo so that the gearshift fork shafts can be installed easily.

NOTE:

When replacing the gearshift cam stopper bolt @, apply a small quantity of THREAD LOCK "1342" to the threaded part of the bolt.

-tta

99000-32050: THREAD LOCK "1342"

• Hook the gearshift cam stopper spring.

CRANKCASE

When reassembling the crankcase pay attention to the following points:

• Remove sealant material on the mating surfaces of right and left halves of crankcase and thoroughly remove oil stains.

• Apply SUZUKI BOND NO.1207B uniformly to the mating surface of the left half of the crankcase, and assemble the cases within few minutes.

~99104-31140:

SUZUKI BOND NO.1207B

• Fit the dowel pins

CD on the right half as shown in photo.

• Apply engine oil to conrod big end of the crankshaft and all parts of the transmission gears.

• After the crankcase bolts have been tightened, check if driveshaft and countershaft rotate smoothly.

• If a large resistance is felt to rotation, try to free the shafts by tapping the driveshaft or countershaft with a plastic hammer.

CAM DRIVEN GEAR

• Install the gearshift pawls into the cam driven gear. The large shoulder @ must face to the outside as shown in the illustration.

• When installing the cam guide @ and pawl lifter @, apply a small quantity of THREAD LOCK "1342" to the securing screws @ .

ENGINE 3-46

3-47 ENGINE

GEARSHIFT SHAFT

• Fit a spring to the gearshift shaft correctly.

• Install the gearshift shaft. Match the center teeth of the gear on the gearshift shaft with the center teeth on the cam driven gear as shown.

NOTE:

When replacing the gearshift arm stopper G), apply a small quantity of THREAD LOCK SUPER "1303" to its threaded part and tighten it to the specified torque. (See page 7-24.)

"1303"

• Fit the dowel pins @ and new gasket.

• Fit the gearshift cover and tighten the bolts diagonally.

NOTE:

After the gearshift cover and gearshift lever have been fitted, confirm that gear change is normal while turning the countershaft and driveshaft. If gear change is not obtained, it means that assembly of gears or installation of gearshift fork is incorrect. If this is the case, disassemble and trace the mistake.

NEUTRAL POSITION INDICATOR SWITCH

• Install the neutral position indicator switch spring @ and switch contact @.

• Install the neutral position indicator switch with two screws.

• Install the breather cover.

OIL PUMP

• Before mounting oil pump, apply engine oil to the sliding surfaces of the case, outer rotor, inner rotor and shaft.

• Apply a small quantity of THREAD LOCK"

1342"

to the oil pump mounting screws. tG:lI99000-320S0: THREAD LOCK

"1342"

• Tighten the oil pump mounting screws.

• Fix the oil pump driven gear with the circlip.

NOTE:

After installing the oil pump driven gear, rotate the pump gear by hand to see if it turns smoothly.

• Fix the idle gear with the circlip.

CAM DRIVE CHAIN AND PRIMARY DRIVE

GEAR

• Engage the cam drive chain.

• Fit the key

CD in the key slot on the crankshaft, then install the primary drive gear and nut.

• Tighten the primary drive gear nut to the specified torque with the special tool.

lib

09910-20116: Conrod holder

~

N-m (10.0 kg-m, 72.Slb-ft)

NOTE:

This nut has left-hand thread nut.

ENGINE 3-48

3-49 ENGINE

CLUTCH

CD o

Clutch re l: ase pinion

Clutch re

I ase arm e rack

@ Clutch rele:sSure plate

@ Clutch pre hub

®

Clutch sleeve

®

Washer seat

(j) d washer

Concave . late

®

Clutch dhr.IV;;r

No.2 (T

IC

~Iate,

1 pc)

®

~

S topper ring

"'" Clutch drive

~

@

Clutch

. drive plate . ,

.

No 2 (1 pc) plate.

Primary driven plate.

No 1 (7 pcs

) gear ass y

)

~hecoperly installed_

• Insta

II the thrust CD. . ear assembly.

• Install the space . gear ap-

NOTE:

. ply engine oil to bot

,

0-

'

• Insta II the thrust washer lb.

• Install t he clute h sleeve hub an d lock washer @.

rt@

oflock

NOTE: . the lock washer @ align the

When installing , f clutch sleeve washer WI s I

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

,roob

09920-53740: Clutch sleeve hub holder

• After tightening the clutch sleeve hub nut, be sure to lock the nut by firmly bending the tongue of the lock washer.

• Install the clutch drive plates and driven plates one by one.

• Install the clutch pressure plate.

• Tighten the clutch spring mounting bolts diagonally to the specified torque with the special tool.

lib

09910-2011 6: Conrod holder

• Fit the dowel pins.

I

A

CAUTION I

I

Use a new gasket to prevent oil leakage.

• Engage the teeth of clutch release rack with those of pinion gear at the clutch cover side, and replace clutch cover.

Make sure that the rack and pinion gear engage positively. To install the cover, tap lightly with plastic hammer, and tighten the bolts.

G): Gasket

ENGINE 3-50

3-51 ENGINE

STARTER CLUTCH AND GENERATOR

• Install the crankcase oil separator and spacer

CD.

• Tighten the ring nut to the specified torque with the special tools .

• MOl.

09917-23711: Ring nut socket wrench

09910-2011 6: Conrod holder

• Install the starter gear and thrust washer.

• Degrease the tapered portion of the generator rotor and also the crankshaft.

• Fil the key @ in the key slot on the crankshaft, then install the generator rotor.

• Apply a small quantity of THREAD LOCK SUPER" 1303" to the threaded part of rotor bolt.

ENGINE 3·52

• Tighten the generator rotor bolt to the specified torque with the 36 mm off-set wrench.

• Install the starter torque limiter and idle gear.

• Install the starter motor.

• Fit the dowel pin and install the new gasket.

• Install the generator cover.

OIL RING

Install the spacer G) into the oil ring groove first. Then install both side rails @, one on each side of the spacer. 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.

--f-+±:"---G)

CORRECT

3·53 ENGINE

TOP RING AND 2ND RING

Top and 2nd rings differ in the shape of the ring face. Top and 2nd rings have a letter "R" or "RN" marked on the side.

Be sure to bring the marked side to top when fitting them to the piston.

• Position the gaps of the three rings as shown. Before inserting piston into the cylinder, check that the gaps are so located. • 2nd ring

• Lower side rail

EX.

I

• Upper side rail

I • Top ring

IN. • Spacer

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

• Rub a small quantity of SUZUKI MOLY PASTE onto the piston pin.

~99000-25140:

SUZUKI MOLY PASTE

• When fitting the piston, turn arrow mark

CD on the piston head to exhaust side.

• Fit the piston pin circlips with long-nose pliers.

I A CAUTION I

Use new piston pin circlip to prevent circlip failure which will occur with a bent one.

• Fit the dowel pins @ to the crankcase and attach a new gasket.

I ACAUTIONj

I

Use a new gasket to prevent oil leakage.

• Hold each piston ring with properly position, and insert the piston into the cylinder.

NOTE:

When mounting the cylinder, keep the camshaft drive chain

CD taut. The camshaft drive chain must not be caught between cam drive chain sprocket and crankcase when crankshaft is rotated.

• Install the cam chain guide.

NOTE:

There is a holder for the bottom end of the cam chain guide cast in the crankcase. Be sure that the cam chain guide @ is inserted proper/yo

• Temporarily tighten the cylinder base nuts.

• Fit the dowel pins @ to the cylinder and attach a new gasket.

I

A.

CAUTION I

Use a new cylinder head gasket to prevent oil leakage.

Do not use the old gasket.

• Place the cylinder head on the cylinder.

• Cylinder head bolts and new gaskets must be fitted in the correct position, as shown in the photograph.

@: 200 mm bolt

@: 190 mm bolt

©:

180 mm bolt

NOTE:

Apply engine oil to the new gaskets before installing.

• Fasten the cylinder head by tightening the bolts and nuts diagonally. Tighten each bolt and nut to the specified torque.

Cylinder head nut: 25 N'm (2.5 kg-m, 18.0 Ib-ft)

ENGINE 3·54

3·55 ENGINE

• After tightening the cylinder head bolts and nuts, tighten the cylinder base nut to the specified torque.

~Cylinder base nut: 10 N'm (1.0 kg-m, 7.0 Ib-ft)

CAMSHAFT

• Turn the crankshaft counterclockwise with the box wrench and align liT" line

CD on the generator rotor with the center of hole on the generator cover keeping the camshaft drive chain pulled upward.

I

A

CAUTION I

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

• Install the C-ring @ into the ring groove of the cylinder head.

NOTE:

Apply grease on the cam sprocket locating pin and install the pin into the camshaft.

• Engage the chain on the cam sprocket with the locating pin hole @ at two o'clock position.

NOTE:

Do not rotate the generator rotor while doing this. When the sprocket is not positioned correctly, turn the sprocket. When installing the camshaft into the cam sprocket, pay attention not to dislodge the locating pin or it may fall into the crankcase.

• Align the engraved line mark @ on the camshaft so it is parallel with the surface of the cylinder head.

• Fit the lock washer so that it is covering the locating pin.

• Apply THREAD LOCK SUPER" 1303" to the cam sprocket bolts and tighten them to the specified torque.

• Bend up the washer tongue positively to lock the bolts.

• Apply SUZUKI MOLY PASTE to the camshaft journals and cam faces.

~99000-25140:

SUZUKI MOLY PASTE

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

• Fit the dowel pins

CD and camshaft end cap @ to the cylinder head side.

• Apply SUZUKI BOND NO.1207B uniformly to the mating surface of the cylinder head cover, and install the cylinder head cover within few minutes.

• Fit the two gaskets @ to the head cover bolts correctly as shown in Fig.

I

A

CAUTION I

[ Use a new gasket to prevent oil leakage.

NOTE:

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

ENGINE 3-56

3·57 ENGINE

• Lightly tighten the cylinder head cover bolts sequentially in the ascending order of numbers, and then if everything is satisfactory, tighten securely with a torque wrench to the specified torque.

• Turn the slotted end of the chain tensioner adjuster to lock it with a screwdriver in the clockwise direction.

• Install the chain tensioner adjuster on the cylinder.

CD:

10 N·m (1.0 kg-m, 7.0 Ib-ft)

• Turn back and pull out the screwdriver from the chain tensioner adjuster. As the cylinder turns, the tensioner rod is advanced under spring force and pushes the tensioner against the cam drive chain.

NOTE:

The cam drive chain tensioner adjuster is maintained at the proper tension by an automatically adjusted tensioner. Before installing the cam drive chain tensioner adjuster, inspect the smooth movement.

• Tighten the tensioner adjuster cap bolt @.

@: 6 N"m (0.6 kg-m, 4.5 Ib-ft)

• Install the oil pipe and tighten the union bolt to the specified torque.

@: 23 N·m (2.3 kg-m, 16.5 Ib-ft)

@: 20 N·m (2.0 kg-m, 14.5 Ib-ft)

4·1 FUEL AND LUBRICATION SYSTEM

FUEL SYSTEM

When turning starter motor, negative pressure is generated in the combustion chamber. This negative pressure works on the diaphragm of fuel valve through passage way provided in the carburetor main bore and vacuum hose, and diaphragm builds up a negative pressure which is higher than the spring pressure. Valve in the fuel valve is forced to open due to diaphragm operation, and thus allows fuel to flow into carburetor float chamber.

Fuel tank

Fuel hose----I'::::::::::I l::::::::I----Vacuum hose vacuum~

Fuel •

FUEL AND LUBRICATION 4-2

FUEL VALVE

FUEL VALVE MECHANISM

A valve is provided at the end of the fuel valve lever and can switch over to "ON", "PRI" and "RES"_

t

FUe

,

"ON" position

"PRI" position

FUEL VALVE/FUEL FILTER REMOVAL

• Remove the frame cover and seat. (Refer to pages 5-1 and 2.)

• Remove the fuel tank. (Refer to page 4-3.)

• Remove the fuel valve by removing the mounting bolts.

AWARNING

Gasoline is very explosive. Extreme care must be taken.

Gaskets and O-ring must be replaced with new ones to prevent fuel leakage.

"RES" position

4·3 FUEL AND LUBRICATION SYSTEM

INSPECTION AND CLEANING

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

FUEL TANK

FUEL TANK REMOVAL

• Remove the frame cover and seat. (Refer to pages 5-1 and 2.)

• Turn the fuel valve to "ON" position.

• Remove the fuel tank mounting bolts

CD.

• Slide the fuel tank backward and lift up it after disconnecting the fuel hose @ and vacuum hose @.

• Remove the fuel tank.

A WARNING

Gasoline is very explosive. Extreme care must be taken.

CARBURETOR

CONSTRUCTION

FUEL AND LUBRICATION 4·4

CD

Top cap

@ Spring

@ Spring seat

@ E-ring

®

Washer

®

Jet needle

(j) a-ring

®

Diaphragm

®

Piston valve

@ Needle jet

®

Main jet

@ Pilot jet

@ Main air jet

@ Starter plunger

@ Pilot screw

@ a-ring

@ a-ring

@ Float

® a-ring

®

Drain screw

4·5 FUEl AND LUBRICATION SYSTEM

SPECIFICATIONS

ITEM

Carburetor type

Bore size

I.D. No.

Idle r/min.

Float height

Main jet

Jet needle

Needle jet

Throttle valve

Pilot jet

Starter jet

Pilot screw

Throttle cable play

(pulling cable)

Starter cable play

E-02,04,34

MIKUNI

BST40SS

40 mm

32EO

1 500± 100 r/min

14.7± 1.0 mm

(0.58 ± 0.04 in)

(M.J.)

(J.N.)

(N.J.)

(Th.V.)

# 140

6F19-3rd

Y-5

#95

(P.J.)

(G.S.)

(P.S.)

#42.5

#40

PRE-SET

(1112

turns back)

0.5-1.0 mm

(0.02-0.04 in)

0.5-1.0 mm

(0.02-0.04 in)

+--

+--

+--

+--

+--

+--

+--

+--

+--

+--

SPECIFICATION

E-37 E-17,22,24 U-type E-22

+-+-+--

+--

32E8

+--

+--

32E3

+--

+--

32E4

+--

+--

+--

+--

+--

+--

+--

+--

+--

+--

+--

+--

+-+--

PRE-SET PRE-SET

(1.0 turn back)

(1118

turns back)

+-+--

+--

+--

+--

COUNTRY OR AREA

E-02: U.K.

E-03: U.S.A.

E-04 : France

E-1 7 : Sweden

E-1 8 : Switzerland

E-22 : Germany

E-24 : Australia

E-28 : Canada

E-33 : California (U.S.A.)

E-34: Italy

E-37 : Brazil

FUEL AND LUBRICATION 4·6

ITEM

Carburetor type

Bore size

I.D. No.

Idle r/min.

Float height

Main jet

Jet needle

Needle jet

Throttle valve

Pilot jet

Starter jet

Pilot screw

Throttle cable play

(pulling cable)

Starter cable play

(M.J.)

(J.N.)

(N.J.)

(Th.V.)

(P.J.)

(G.S.)

(P.S.)

E-03

MIKUNI

BST40SS

40 mm

32E1

1 500± 100 r/min

14.7± 1.0 mm

(O.58±0.04 in)

# 140

6F23

Y-5M

#95

#425

#40

PRE-SET

0.5-1.0 mm

(O.02-0.04 in)

0.5-1.0 mm

(0.02-0.04 in)

1.0. NO. LOCATION

Each carburetor has I.D. Number

CD printed on the carburetor body according to its specification.

+-

+-

+-

+-

+-

+-

+-

SPECIFICATION

E-33 E-28

++-

+-

32E6

+-

+-

+-

+-

32E5

+-

E-18

+-

+-

32E2

1 500± 50 r/min

++-

#140

6F19-3rd

Y-5

+-

# 137.5

6H21-4th

+-

+-

#42.5

+-

+-

+-

(1112

PRE-SET PRE-SET turns back) (1.0 turn back)

++-

+++-

I 1i----1f--+-'G)

4-7 FUEL AND LUBRICATION SYSTEM

SLOW SYSTEM

This system supplies fuel during engine operation with throttle valve

CD closed or slight opened. The fuel from float chamber @ is metered by pilot jet @ where it mixes with air coming in through pilot air jet @ . This mixture, rich with fuel, then goes up through pilot passage to pilot screw

® .

A part of the mixture is discharged into the main bore out of bypass ports

® .

The remainder of mixture is metered by pilot screw

® and sprayed out into the main bore through pilot outlet

(j) .

--------,

\

'! d.L.

_a,

( __ J

I

¢=:=J

Air

<18::::::::;::::;::::<1 Fuel/Air mixture

4

Fuel

FUEL AND LUBRICATION 4·8

MAIN SYSTEM

As throttle valve

CD is opened, engine speed rises, and this increases negative pressure in the venturi

®.

Consequently the piston valve @ moves upward.

Meanwhile, the fuel in float chamber @ is metered by main jet @ , and the metered fuel enters needle jet

® , in which it mixes with the air admitted through main air jet

® to form an emulsion.

The emulsified fuel then passes through the clearance between needle jet

® and jet needle

(J) ,

and is discharged into the venturi

®, in which it meets main air stream being drawn by the engine.

Mixture proportioning is accomplished in needle jet

® ; the clearance through which the emulsified fuel must flow in large or small, depending ultimately on throttle position.

<18::::::::::::::::::::::J

Fuel/Air mixture

~

Fuel

4-9 FUEL AND LUBRICATION SYSTEM

STARTER SYSTEM

Pulling the starter cable G) , fuel is drawn into the starter circuit from the float chamber @ _

Starter jets (@, @) meters this fuel, which then flows into fuel pipe

® and mixes with the air coming from the float chamber. The mixture, rich in fuel content, reaches starter plunger

® and mixes again with the air coming through a passage extending from behind the diaphragm.

The two successive mixings of fuel with air are such that proper fuel/air mixture for starting is produced when the mixture is sprayed out through starter outlet port

(j)

into the main bore.

~Air

<Q:::::O::::::::::::::1 Fuel/Air mixture

_ Fuel

FLOAT SYSTEM

Floats G) and needle valve

0 are associated with the same mechanism, so that, as the floats G) move up and down, the needle valve

0 too moves likewise.

When fuel level is up in float chamber @ , floats G) are up and needle valve

0 remains pushed up against valve seat.

Under this condition, no fuel enters the float chamber @ .

As the fuel level falls, floats G) go down and needle valve o unseats itself to admit fuel into the chamber @ .

In this manner, needle valve

0 admits and shuts off fuel alternately to maintain a practically constant fuel level inside the float chamber @ .

r---"/

:

Lr7

(---_._--"\

\

~ d-L . ___ .

)'

.'

)

: rLJ

~

'-'....-,....--J ..

."Y"··v

• Fuel

REMOVAL

Refer to page 3-4.

OISASSEMBL Y

NOTE:

Before disassembly, prepare a clean and well lit work place where carburetor components can be layed out neatly and won't get lost.

• Remove the carburetor top cap

CD.

IA

CAUTION

I

Do not blow the carburetor body with compressed air, before removing the diaphragm. It may cause a damage to the diaphragm.

• Remove the piston valve return spring @ and piston valve with diaphragm @.

FUEL AND LUBRICATION 4·10

• Remove the jet needle @ out of the piston valve.

>~-'1'P'£

@

• Remove the float chamber body

®.

4·11 FUEL AND LUBRICATION SYSTEM

• Remove the float assembly G) and needle valve

0.

! ACAUTION!

Do not use a wire for cleaning the valve seat.

• Remove the main jet @, pilot jet @ and pilot screw @

(Refer to PILOT SCREW REMOVAL of page 4-12 for E-03,

18 and 33 models).

! ACAUTION!

Do not use a wire for cleaning of passage and jets.

NOTE:

Before removing the pilot screw @, slowly turn the pilot screw in clockwise and count the number of turns until the screw is lightly seated. Make a note of how many turns were made so the screw can be reset correctly after removing.

• Remove the main air jet @.

! ACAUTION!

I

Do not use a wire for cleaning of jet.

CARBURETOR CLEANING

AWARNING

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

NOTE:

Remove the pilot screw as described next page before cleaning.

• 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.

Iii.

CAUTION

I

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.

• Install a new cap over the pilot screw opening. (for

E-03, 18,33 models)

PILOT SCREW REMOVAL

(FOR E-03,18 AND 33 MODELS)

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

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

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

• Slowly turn the pilot screw 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 with the spring, washer, and

O-ring.

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

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

FUEL AND LUBRICATION 4-12

4·13 FUEL AND LUBRICATION SYSTEM

INSPECTION

Check the following items for any damage.

* Pilot jet

* Main jet

* Main air jet

* Pilot air jet

* Needle valve

* Starter jet

* Gasket and a-ring

* Throttle shaft oil seal

* Needle jet air bleeding hole * Diaphragm

* Float * Pilot outlet and by-pass holes

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.

FLOAT HEIGHT ADJUSTMENT

To check the float height, invert the carburetor body, with the float arm kept free, measure the height @ while float arm is just in contact with needle valve by using calipers.

Bend the tongue as necessary to bring the height @ to this value.

Float height@: 14.7±1.0 mm (0.58±0.04 in)

.root,

09900-20102: Vernier calipers

CORRECT INCORRECT

THROTTLE POSITION SWITCH (Except for E-03,18,24,28 and 33 models)

• Remove the fuel tank. (Refer to page 4-3.)

Inspect the throttle position switch for continuity with pocket tester. If any abnormality is found, replace the respective switch assemblies with new ones.

Cib

09900-25002: Pocket tester

~

Q range

~

ON (full-throttle) 0

OFF

B

-0

B: Black

NOTE:

When making above test, it is not necessary to start the engine.

REASSEMBLY AND REMOUNTING

Reassemble and remount the carburetor assembly in the reverse order of removal and disassembly.

• When installing the carburetor top cap, align the vacuum ports (CD, @).

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

* Engine idle r/min ................................... Page 2-6

* Throttle cable play ................................. Page 2-6

LUBRICATION SYSTEM AND COOLING SYSTEM

OIL PRESSURE

Refer to page 2-18.

OIL FILTER

Refer to page 2-8.

OIL SUMP FILTER

Refer to page 3-16.

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 4-14

4·15 FUEL AND LUBRICATION SYSTEM

ENGINE LUBRICATION/CYLINDER HEAD COOLING SYSTEM CHART

I

I

I

CAMSHAFT :

,,~,~

"",J

INTAKE AND ' ; ; '

EXHAUST I

CAM FACE

INTAKE ROCKER

ARM SHAFT

,~

AND ROCKER ARM

+

H

CYLINDER HEAD

COVER LEFT·SIDE i.

~H

HH

CYLINDER HEAD t

CYLINDER , n

~H

HH

I

I

I

OIL PIPE

I

CONROD

SMALL

END i.

~H

• H\

I

CYLINDER HEAD

COVER RIGHT·SIDE

I

PISTON l

~

NOZZLE

, l.·~

CYLINDER

WALL

"

, ,

I' •

~

\ I

CONROD BIG

END BEARING

I

I

OIL JET

I

~ r

CRANKSHAFT I

RIGHT·SIDE

I CAMSHAFT l

RIGHT·SIDE JOURNAL r

I

J6

H~

HH

I

OIL HOSE t

I

I OIL COOLER I

STARTER

CLUTCH

I

~

OIL HOSE

CYLINDER

HEAD

COOLING i.

~H

4tH

I

CAM CHAIN

AND CAM

SPROCKET

'\

'\=

\-

~---------------------------------

BY·PASS r - - - - - - -

I

~

OIL FILTER +

COUNTERSHAFT

LEFT·SIDE

BEARING

DRIVESHAFT

~

LEFT-SIDE

BEARING

AND GEARS

OIL JET

I

• •

DRIVES HAFT COUNTERSHAFT

AND GEARS

L _ _ _ _ _ _ _

I

I

OIL PUMP

OIL SUMP

FILTER i.

H~

HH t

I

PRIMARY DRIVEN

GEAR AND CLUTCH PLATES

I

J6

~H

HH

-OIL PAN-

I

I

I

-I

-I

FUEL AND LUBRICATION 4·16

4·17 FUEL AND LUBRICATION SYSTEM

OIL COOLER

CD

Oil cooler

@ O·ring

@ Oil cooler hose

(To cylinder head)

@ Oil cooler hose

(From clutch cover)

®

Oil cooler cover

®

Oil cooler guard

N·m

10 kg-m

1.0

Ib-ft

7.0

REMOVAL

• Drain engine oil. (Refer to page 3-1.)

• Remove the oil cooler hose mounting bolts.

• Remove the oil cooler holder with cooler by removing its mounting bolts.

5·1 CHASSIS

FRAME COVER AND SEAT

REMOVAL AND REMOUNTING

• Remove the right and left frame covers by removing the mounting screws.

• Remove the seat by removing the mounting bolts.

• Remount the seat and frame covers.

FRONT WHEEL

ITEM N·m kg-m Ib-ft

@ 65 6.5 47.0

®

10 1.0 7.0

© 4.5 0.45 3.0

© 23 2.3 16.5

REMOVAL

• Loosen the front axle holder nuts G) and axle shaft @.

• Carefully position a jack under the chassis tubes and raise until the front wheel is slightly off the ground.

• Remove the front wheel by removing the front axle.

NOTE:

Do not operate the brake lever while dismounting the front wheel.

• Remove the disc by removing the mounting bolts.

®

CHASSIS 5·2

CD

Axle holder

@ Speedometer gearbox

@ Bearing (R)

@ Spacer

®

Bearing (L)

®

Dust seal

(j) Spacer

®

Disc

5·3 CHASSIS

INSPECTION AND DISASSEMBLY

WHEEL BEARING

Inspect the play of bearing inner ring by hand while mounted in the wheel.

Rotate the inner ring by hand to inspect if any abnormal noise occurs or rotating smoothly.

Replace the bearing if there is anything unusual.

• Remove the dust seal.

• Drive out the both bearing with the special tool in the following procedures.

iitJ

09941-50111: Bearing remover

• Insert the adapter into the bearing.

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

• Drive out the bearing by knocking the wedge bar.

[ A CAUTION [

The removed bearing should be replaced with new ones.

FRONT AXLE

Check the front axle runout with a dial gauge and replace it if the runout exceeds the limit.

E

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

09900-20701: Magnetic stand

09900-21304: "V"

block set

Service Limit: 0.25 mm (0.010 in)

WHEEL RIM

Make sure that the wheel rim runout does not exceed the service limit when checked as shown.

An excessive runout is usually due to worn or loose wheel bearings and can be reduced by replacing the bearings. If bearing replacement fails to reduce the runout, replace the wheel.

Service Limit

(Axial and Radial)

: 2.0 mm (0.08 in)

SPOKE NIPPLE

Check to be sure that all nipples are tight, and retighten them as necessary.

TIRE (Refer to page 2-12.)

REASSEMBLY AND REMOUNTING

Reassemble and remount the front wheel in the reverse order of removal and disassembly, and also carry out the following steps:

WHEEL BEARING

• Apply grease to the bearings.

• Install the wheel bearings with the special tools.

09924-84521: Bearing installer

NOTE:

First install the wheel bearing for left side.

Bearing (L)

Spacer

Clearance

CHASSIS 5·4

5-5 CHASSIS

BRAKE DISC

• Make sure that the brake disc is clean and free of any greasy matter_ Apply THREAD LOCK SUPER 1/13601/ to the disc mounting bolts and tighten them to the specified torque.

~

1/1360"

• Align the drive lugs

CD to the recesses @ of the wheel hub.

• Before tightening the front axle, position the stopper @ of speedometer gearbox against stopper @.

• Tighten the front axle to the specified torque and then move the front fork up and down.

• Tighten the axle holder nuts to the specified torque.

NOTE:

When tightening the axle holder nuts, first tighten the upper nuts.

47.0 Ib-ftl

Axle holder nut: 10 N·m (1.0 kg-m, 7.0 Ib-ft)

FRONT BRAKE

CD

Piston/cup set

@ Brake hose

@Pad

@ Piston set

ITEM

®

@

©

©

®

®

@

(8l

N'm

10

23

18

2.5

8

23

13

26 kg-m Ib-ft

1.0 7.0

2.3 16.5

1.8 13.0

0.25 1.8

0.8 6.0

2.3 16.5

1.3 9.5

2.6 19.0

CHASSIS 5-6

-+--@

AWARNING

*

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

*

Do not use any brake fluid taken from old. used or unsealed containers. Never 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.

IA

CAUTION

I

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

5-7 CHASSIS

BRAKE PAD REPLACEMENT

• Remove the plug

CD-

• Remove the brake pads by removing the mounting pin @.

I

A CAUTION I

*

Do not operate the brake lever while dismounting the pads_

*

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

• Install the new pads.

AWARNING

Make sure that the pads are properly engaged with the guide plates as shown in photo.

• Tighten the pad mounting pin @ and plug

CD to the specified torque.

Plug: 2.5 N·m (0.25 kg-m, 1.8 Ib-ft)

NOTE:

After replacing the brake pads, pump with the brake lever few times to operate the brake correctly and then check the brake fluid level.

BRAKE FLUID REPLACEMENT

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

• Remove the master cylinder reservoir cap and diaphragm.

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

• Fill the reservoir with fresh brake fluid.

III

Specification and classification: DOT 4

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

• Loosen the bleeder valve and pump the brake lever until no more old brake fluid flows out of the bleeder valve.

• Close the air bleeder valve, and disconnect a clear hose.

Fill the reservoir with fresh brake fluid to the upper end of the inspection window.

I

A CAUTION I

Bleed air in the brake fluid circuit. (Refer to page 2-11.)

CALIPER REMOVAL AND DISASSEMBLY

• Disconnect the brake hose by removing the union bolt and catch the brake fluid in a suitable receptacle.

• Remove the caliper by removing the mounting bolts.

IA

CAUTION

I

Never reuse the brake fluid left over from previous servicing and stored for long periods.

AWARNING

Brake fluid, if it leaks, will interfere with safe running and descolor painted surfaces.

Check the brake hose and hose joints for cracks and oil leakage.

• Remove the brake pad. (Refer to page 5-7.)

• Remove the caliper holder

CD and spring @.

• Place a rag over the piston to prevent its popping out and push out the pistons with an air gun.

IA

CAUTION

I

Do not use high pressure air to prevent piston damage.

• Remove the dust seals and piston seals.

IA

CAUTION

I

Do not reuse the remored seals to prevent fluid leakage.

0 0

0 0

CHASSIS 5·8

5·9 CHASSIS

CALIPER INSPECTION

Inspect the caliper cylinder wall for nicks, scratches or other damage.

Inspect the piston surface for any scratches or other damage. D

D

CALIPER REASSEMBLY AND REMOUNTING

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

• Wash the caliper bores and pistons with specified brake fluid. Particularly wash the dust seal grooves and piston seal grooves.

I

A

CAUTION I

*

Wash the caliper components with fresh brake fluid before reassembly.

*

Do not wipe the brake fluid off after washing the components.

*

When washing the components, use the specified brake fluid. Never use different types of fluid or cleaning solvent such as gasoline, kerosine or the others.

*

Replace the piston seals and dust seals with new ones when reassembly. Apply the brake fluid to both seals when installing them.

• Apply SUZUKI SILICONE GREASE to the caliper axles.

~

SUZUKI SILICONE GREASE

• Tighten each bolt to the specified torque.

~Caliper mounting bolt

CD:

26 N·m (2.6 kg-m, 19.0 Ib-ft)

Pad mounting pin @: 18 N·m (1.8 kg-m, 13.0 Ib-ft)

Plug @: 2.5 N·m (0.25 kg-m, 1.8 Ib-ft)

Brake hose union bolt@: 23 N·m (2.3 kg-m, 16.5 Ib-ft)

Air bleeder valve @: 8 N·m (0.8 kg-m, 6.0 Ib-ft)

NOTE:

Before remounting the caliper, push the piston all the way into the caliper.

IA

CAUTION

I

Bleed air from the system after reassembling the caliper.

(Refer to page 2-11.)

BRAKE DISC INSPECTION

• Remove the front and rear wheels. (Refer to pages 5-2 and 5-27.)

Visually check the brake disc for damage or cracks.

Measure the thickness with a micrometer.

Replace the disc if the thickness is less than the service limit or if damage is found.

'W'

09900-20205: Micrometer (0-25 mm)

Service Limit

Front disc: 3.5 mm (0.14 in)

Rear disc: 4.0 mm (0.16 in)

Measure the runout with a dial gauge.

Replace the disc if the runout exceeds the service limit. lim

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

09900-20701: Magnetic stand

Service Limit

Front and Rear disc: 0.3 mm (0.012 in)

• Remove the disc. (Refer to pages 5-3 and 5-29.)

• Install the disc. (Refer to pages 5-5 and 5-32.)

CHASSIS 5·10

5·11 CHASSIS

MASTER CYLINDER REMOVAL AND

DISASSEMBL Y

• Remove the brake lever cover and rear view mirror.

• Remove the brake lever.

• Disconnect the front brake switch lead wires.

• Place a rag underneath the union bolt on the master cylinder to catch any spilled drops of brake fluid. Remove the union bolt and disconnect the brake hose/master cylinder joint.

I

A CAUTION I

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

• Remove the master cylinder assembly.

• Remove the front brake switch.

• Remove the reservoir cap and diaphragm.

• Drain brake fluid.

• Remove the dust boot.

• Remove the circiip with the special tool. lim

09900-06108: Snap ring pliers

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

MASTER CYLINDER INSPECTION

Inspect the master cylinder bore for any scratches or other damage.

Inspect the piston surface for any scratches or other damage.

Inspect the primary cup, secondary cup and dust seal for wear or damage.

CHASSIS 5·12

5·13 CHASSIS

MASTER CYLINDER REASSEMBLY AND

REMOUNTING

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

! ACAUTION!

*

Wash the master cylinder components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to wash them.

*

Do not wipe the components with a rag.

*

Apply brake fluid to the cylinder bore and all the component to be inserted into the bore.

• When remounting the master cylinder on the handlebars, align the master cylinder holder's lower mating surface

CD with punched mark

0 on the handlebars and tighten the upper clamp bolt first as shown.

10 N·m (1.0 kg-m, 7.0 Ib-ft)

! ACAUTION!

Bleed air from the system after reassembling master cylinder. (Refer to page 2-11.)

Upper clamp bolt

"UP" mark

--H-

Clearance

FRONT FORK

®

I

n·

~

®

CHASSIS 5-14

(1)----1

G) Spacer

@ Washer

@ Spring

@ Damper rod

®

Spring

®

Inner tube

(j) Inner tube metal

®

Boot

®

Stopper ring

@ Dust seal

@ Oil seal

@ Retainer

@ Outer tube metal

@ Oil lock piece

@ Outer tube

@ Front axle holder

1,"1

©r1C'\

--;;)-) i~

~

")/

@ r~ ~

REMOVAL AND DISASSEMBLY

• Remove the front wheel. (Refer to page 5-2.)

• Remove the front brake caliper. (Refer to page 5-8.)

• Remove the front brake hose clamp bolt G).

• Remove the speedometer cable guide bolt @.

ITEM N·m kg-m Ib-ft

® 23 2.3 16.5

@ 30 3.0 21.5

© 10 1.0 7.0

5·15 CHASSIS

• Slightly loosen the front fork cap bolt

CD after loosening the front fork upper clamp bolt @ to facilitate later disassembly.

• Remove the front fork by loosening the lower clamp bolts

@.

• Remove the front fork cap bolt

CD, spacer @, washer

® and spring

®.

• Invert the fork and stroke it several times to drain fork oil.

• Hold the fork inverted for a few minutes to drain fork oil.

• Remove the damper rod bolt with a 8 mm hexagon wrench and special tools.

,·Wah

09940-34520: "T" handle

09940-34592: Attachment "G"

• Remove the damper rod with spring.

• Remove the boot by loosening the clamp screws.

• Remove the dust seal stopper ring.

• Separate the inner tube from the outer tube.

I A. CAUTION I

* The removed dust seal and oil seal should be replaced.

* When separating the inner tube from the outer tube, both anti-friction metals may be damaged and must be replaced with new ones.

INSPECTION

FORK SPRING

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

Service Limit: 548 mm (21.6 in)

INNER TUBE AND OUTER TUBE

Inspect the inner tube sliding surface for any scuffing and check for bend. Inspect the outer tube sliding surface for any scuffing.

CHASSIS 5·16

5·17 CHASSIS

DAMPER ROD RING

Inspect the damper rod ring for wear or damage.

REASSEMBLY AND REMOUNTING

Reassemble and remount the front fork in the reverse order of removal and disassembly, and also carry out the following steps:

INNER TUBE METAL

• Install the metal by hand as shown in the illustration.

[ACAUTION[

Use special care to prevent damage to the "Teflon" coated surface of the Anti-friction metal when mounting it.

OUTER TUBE METAL, OIL SEAL AND DUST SEAL

• Clean the metal groove of outer tube and metal outer surface.

• Apply grease to the lip of new oil seal @.

• Install the outer tube metal G), oil seal retainer @, oil seal

@ and dust seal @ .

• Q,

09940-52860: Front fork oil seal installer

[ A CAUTION [

Use special care to prevent damage to the "Teflon" coated surface of the Anti-friction metal when mounting it.

• Install the dust seal stopper ring

®.

[ A CAUTION [

Make sure that the oil seal stopper ring fitted securely.

®

~.I-®

®

@

CD

CHASSIS 5·18

DAMPER ROD BOLT

Apply THREAD LOCK" 1342" to the damper rod bolt and tighten it to the specified torque with the special tools and

8-mm hexagon wrench.

~

THREAD LOCK "1342"

.@u

09940-34520: "TH handle

09940-34592: Attachment HGH

( ~:

'----!

THREAD LOCK" 1342"

B

FORK OIL

• For the fork oil, be sure to use a front fork oil whose viscosity rating meets specifications below.

Fork oil type: Fork oil # 10

Fork oil capacity: 565 ml (19.1/19.9 US/Imp oz)

• Hold the front fork vertical and adjust the fork oil level with the special tool.

NOTE:

When adjusting oil level, remove the fork spring and compress the inner tube fully. em

09943-74111: Fork oil level gauge

Oil level: 164 mm (6.5 in)

FORK SPRING

• Install the fork spring close pitch side up.

-

Upper

5·19 CHASSIS

FRONT FORK REMOUNTING

• Align the top surface

CD of the inner tube to the top surface @ of the steering stem upper bracket.

• Tighten each bolt to the specified torque.

@: 23 N·m (2.3 kg-m, 16.5 Ib-ftl

Upper clamp bolt @: 29 N·m (2.9 kg-m, 21.0 Ib-ftl

Lower clamp bolt @: 26 N·m (2.6 kg-m, 19.0 Ib-ft)

CHASSIS 5-20

STEERING

CD

Handlebar clamp o

Handlebar holder

@Cap

@ Damper (Upper)

®

Steering stem upper bracket

®

Damper (Lower)

(}) Steering stem nut

®

Bearing (Upper)

®

Bearing (Lower)

@ Steering stem lower bracket

@---ff.

®--~\

REMOVAL AND DISASSEMBLY

• Remove the front wheel. (Refer to page 5-2.)

• Remove the front fork. (Refer to page 5-14.)

• Remove the speedometer cable clamp and the front fender.

ITEM

@

@

©

©

®

N-m kg-m Ib-ft

23 2.3 16.5

90 9.0 65.0

25 2.5 18.0

29 2.9 21.0

26 2.6 19.0

5·21 CHASSIS

• Remove the headlight cover by removing the three screws.

• Remove the lead wire cover

CD.

• Disconnect each lead wire coupler.

• Remove the headlight bracket with headlight by removing the four bolts.

• Remove the front brake master cylinder with brake hose.

• Remove the left turn signal light.

• Unlock the clamps.

• Remove the right turn signal light.

• Remove the headlight bracket holders.

• Remove the speedometer cable

CD.

• Remove the speedometer by removing the nuts.

• Remove the throttle grip case screws.

• Disconnect the throttle cables.

• Remove the left handlebar switch case screws.

• Disconnect the starter cable.

CHASSIS 5·22

5·23 CHASSIS

• Remove the clutch lever cover.

• Remove the clutch cable G).

• Remove the indicator light panel @.

• Remove the ignition switch mounting bolts with the special tools.

,Qu

09930-11920: Torx bit JT40H

09930-11940: Bit holder

• Remove the handlebars by removing the four mounting bolts.

• Remove the handlebar holder by removing the mounting nuts.

• Remove the steering stem upper bracket by removing the stem head nut.

• Loosen the steering stem nut with the special tools.

11m

09940-14911: Steering stem nut socket wrench

09940-14960: Steering stem nut socket

• Remove the steering stem lower bracket.

NOTE:

Hold the steering stem lower bracket by hand to prevent it from falling.

• Remove the upper bearing.

• Remove the steering stem lower bearing with a chisel.

Iii.

CAUTION

I

The removed bearing should be replaced with a new one.

• Remove the steering stem bearing races, upper and lower with the special tools.

11m

09941-54911: Steering race remover

09941-74910: Steering bearing remover and installer

CHASSIS 5-24

5-25 CHASSIS

INSPECTION

Inspect the removed parts for the following abnormalities.

* Handlebars distortion

* Handlebar clamp wear

* Race wear and brinelling

* Abnormal noise of bearing

* Distortion of steering stem

Inspect the play of dampers by hands while fixing it in the steering stem upper bracket. If the play can be found, replace the dampers.

REASSEMBLY AND REMOUNTING

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

BEARING RACES

• Press in the upper and lower bearing races with the special tool.

lim

09941-34513: Steering outer race installer

BEARING

• Press in the lower bearing with the special tool.

,·£oh

09925-18010: Steering bearing installer

,rooh---+

• Apply grease to the upper and lower bearings.

~99000-25030:

SUZUKI SUPER GREASE "A"

STEM NUT

• Tighten the steering stem nut to 45 N·m (4.5 kg-m, 32.5

Ib-ft) with the special tools.

lim

09940-14911: Steering stem nut wrench

09940-14960: Steering stem nut socket

• Turn the steering stem bracket about five or six times to the left and right until it locks in position so that the taper roller bearing will be seated properly_

• Turn back the stem nut by 1/4-1/2 turn.

NOTE:

This adjustment will vary from motorcycle to motorcycle.

• Tighten the steering stem nut to the specified torque.

NOTE:

Before tightening the steering stem nut, install the front fork temporarily.

.

...

"

."'"

CHASSIS 5-26

1/4-1/2 turn

• Tighten the handlebar holder nuts to the specified torque.

NOTE:

Before tighten the handlebar holder nuts, install the handlebars temporarily.

HANDLEBARS

• Set the handlebars to match its punched mark to the mating face of the holder.

• Secure the each handlebar clamp in such a way that the clearances @ ahead and behind of the handlebars are equalized.

I

A CAUTION

I

After performing the adjustment and installing the steering stem upper bracket, "rock" the front wheel assembly forward and back to ensure that there is no play and that the procedure was accomplished correctly. Finally check to be sure that the steering stem moves freely from left to right with own weight. If play or stiffness is noticeable, re-adjust the steering stem nut.

5-27 CHASSIS

REAR WHEEL

G) Chain adjuster

@Disc

@ Dust seal

@ Bearing

®

Spacer

®

Damper o

Sprocket drum

®

Rear sprocket

®

Spacer

@ Bearing

@ Dust seal

@ Spacer

@ Rear axle

@ Cotter pin (For Canada and U.S.A.)

REMOVAL

• Remove the cotter pin. (For Canada and U.S.A.)

• Loosen the axle nut.

• Support the motorcycle with a jack.

• Remove the axle nut and axle.

,

, c

ITEM N'm kg-m Ib-ft

* 100 *10.0 *72.5

®

110 11.0 79.5

@ 4.5 0.45 3.0

© 23 2.3 16.5

(Q) 27 2.7 19.5

NOTE:

Asterisk mark (*) indicates the

Canada and U. S.A. models.

• Remove the rear wheel by disengaging the drive chain.

Ii!.

CAUTION

I

Do not operate the brake pedal while dismounting the rear wheel.

• Remove the rear sprocket mounting drum from the wheel.

• Remove the cushions.

• Remove the spacer

CD.

• Remove the rear sprocket by removing the mounting nuts and bolts.

• Remove the dust seal with the special tool .

• fcfoh

09913-50121: Dust seal remover

CHASSIS 5-28

5-29 CHASSIS

• Remove the brake disc by removing the mounting bolts.

INSPECTION AND DISASSEMBLY

REAR WHEEL .............................. Refer to page 5-10.

WHEEL BEARING AND SPROCKET DRUM BEARING

Inspect the play of bearing inner ring by hand while mounted in the wheel or sprocket drum. Rotate the inner ring by hand to inspect any abnormal noise occurs or rotating smoothly. Replace the bearing if there is anything unusual.

Play

~~F=~Play

Remove the both bearing with the special tool in the following procedures.

• Insert the adapter into the bearing.

,gob

09941 -50111: Bearing remover

• After inserting the wedge bar from the opposit side, lock the wedge bar in the slit of the adapter.

• Drive out the bearing by hammering the wedge bar.

I

A

CAUTION I

The removed bearings should be replaced with new ones.

CHASSIS 5·30

• Remove the sprocket drum bearing with the special tool.

.M'Oli

09913-75830: Bearing remover

IA

CAUTION

I

The removed bearing should be replaced with a new one.

REAR AXLE

Using a dial gauge, check the rear axle for runout.

If the runout exceeds the limit, replace the rear axle.

I!ib

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

09900-20701: Magnetic stand

09900-21304: "V" block set

Service Limit: 0.25 mm (0.010 in)

REAR SPROCKET

Inspect the sprocket teeth for wear. If they are worn as illustrated, replace the sprocket and drive chain.

REAR SPROCKET DAMPER

Inspect the dampers for wear and damage. If any defects are found, replace the dampers as a set.

Normal wear Excessive wear

5-31 CHASSIS

REASSEMBLY AND REMOUNTING

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

WHEEL BEARING

• Apply grease to the bearings.

~99000-25030:

SUZUKI SUPER GREASE "A"

• Install the wheel bearings with the special tools .

• MOl.

09924-84510: Bearing installer

09924-84521: Bearing installer

NOTE:

First install the bearing for right side. Seal side of bearing goes toward outside.

Bearing (R)

Bearing (L)

Spacer

Clearance

• Install the rear sprocket drum bearing by using a bearing installer.

NOTE:

Seal side of bearing goes toward outside.

BRAKE DISC

• Apply THREAD LOCK SUPER

"1360"

to the disc bolts and tighten them to the specified torque.

NOTE:

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

SPROCKET

• Tighten the sprocket nuts to the specified torque.

~Sprocket nut: 27 N·m (2.7 kg-m, 19.5 Ib-ftl

NOTE:

Face the stamped mark on the sprocket to outside.

REAR AXLE NUT

• Adjust the chain slack after rear wheel installation. (Refer to page 2-9.)

• Tighten the axle nut to the specified torque.

~Axle nut: 100 N·m (10.0 kg-m, 72.5 Ib-ftl

... For Canada and U.S.A.

: 110 N·m (11.0 kg-m, 79.5Ib-ftl

... For the others

CHASSIS 5·32

5·33 CHASSIS

REAR BRAKE

ITEM N·m kg-m

® 18 1.8

@ 8 0.8

© 23 2.3

© 13 1.3

® 10 1.0

® 23 2.3

~ 18 1.8

Ib-ft

13.0

6.0

16.5

9.5

7.0

16.5

13.0

CD

Piston

@Pad

@ Insulator

@Shim

®

Caliper holder

®

Reservoir tank

(j) Reservoir tank hose

®

Brake hose

®

Piston/cup set

AWARNING

*

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

*

Do not use any brake fluid taken from old, used or unsealed containers. Never 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.

IA

CAUTION

I

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

BRAKE PAD REPLACEMENT

• Remove the brake pad mounting pins

CD.

• Remove the inside pad first.

• Slide the caliper housing to outside then remove the pad

@.

Ill.

CAUTION

I

*

Do not operate the brake pedal while dismounting the pads.

*

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

• Install the new pads correclty.

• Tighten the pad mounting pin

CD to the specified torque.

NOTE:

After replacing the brake pads, pump with brake pedal few times to operate the brake correctly and then check the brake fluid level.

BRAKE FLUID REPLACEMENT

• Remove the reservoir tank mounting bolt.

• Replace brake fluid in the same manner of the front brake.

(Refer to page 5-7.)

ill

Specification and classification: DOT 4

Ill.

CAUTION

I

Bleed air in the brake fluid circuit. (Refer to page 2-11.J

CHASSIS 5·34

5-35 CHASSIS

CALIPER REMOVAL AND DISASSEMBLY

• Remove the rear wheel. (Refer to page 5-27.)

• Place a rag underneath the union bolt on the brake caliper to catch any spilled drops of brake fluid.

• Remove the union bolt and catch brake fluid in a suitable receptacle.

I A CAUTION I

Never reuse the brake fluid left over from previous servicing and stored for long periods.

AWARNING

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

• Remove the caliper with caliper holder.

• Remove the caliper holder

W.

• Remove the pads. (Refer to page 5-34.)

• Place a rag over the piston to prevent popping up. Force out the piston with an air gun.

IA

CAUTION

I

Do not use high pressure air to prevent piston damage_

• Remove the dust seal and piston seal.

IA

CAUTION

I

Do not reuse the removed seals to prevent fluid leakage.

~oo

CHASSIS 5·36

CALIPER AND DISC INSPECTION

Inspect the caliper cylinder bore wall for nicks, scratches or other damage.

Inspect the pistons for damage and wear.

DISC ........................................... Refer to page 5-10.

o

CALIPER REASSEMBLY AND REMOUNTING

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

IA

CAUTION

I

*

Wash the caliper components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to wash them.

*

Apply brake fluid to the caliper bore and piston to be inserted into the bore.

III

Specification and classification: DOT 4

• Tighten the brake hose union bolt to the specified torque.

IA

CAUTION

I

Bleed air from the system after reassembling the caliper.

(Refer to page 2-11.)

. .

~

5-37 CHASSIS

MASTER CYLINDER REMOVAL AND

DISASSEMBL Y

• Place a cloth underneath the union bolt on the master cylinder to catch spilled drops of brake fluid.

• Loosen the rear brake rod lock nut

CD.

• Remove the master cylinder mounting bolts @.

• Disconnect the brake rod by rotating brake rod @.

• Disconnect the brake hose @.

• Remove the reservoir tank by removing the mounting bolt

®.

• Remove the connector by removing the circlip

® .

• rooh

09900-06108: Snap ring pliers

• Remove the O-ring

(j).

I

A CAUTION I

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

• Remove the dust boot.

• Remove the circlip with the special tool.

.rooh

09900-06108: Snap ring pliers

• Remove the rod, piston, primary cup and spring.

MASTER CYLINDER INSPECTION

Inspect the cylinder bore wall for any scratches or other damage.

Inspect the piston surface for scratches or other damage.

Inspect the primary cup for damage.

MASTER CYLINDER REASSEMBLY AND

REMOUNTING

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

IA

CAUTION

I

*

Wash the master cylinder components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to wash them.

*

Apply brake fluid to the cylinder bore and all the internals to be inserted into the bore.

III

Specification and classification: DOT 4

MASTER CYLINDER

• Tighten the bolts and nut to the specified torque. mounting bolt

CD :

10 N·m (1.0 kg-m, 7.0 Ib-ftl

Master cylinder rod lock nut @: 18 N·m (1.8 kg-m, 13.0 Ib-ft)

Brake hose

Union bolt @ : 23 N·m (2.3 kg-m, 16.5 Ib-ftl

IA

CAUTION

I

*

Bleed air from the system after reassembling master cylinder. (Refer to page 2-11.1

*

Adjust the brake pedal height. (Refer to page 2-11.1

CHASSIS 5·38

5-39 CHASSIS

REAR SWINGARM AND S

USPENSION

®

CD

Shock absorber

@ Cushion rod

@ Cushion lever

® Swingar~

®

Chain gUide

®

Chain buffer o

Rear axle

®

Chain cover

REMOVAL

• Remove the frame covers and seat. (Refer to page 5-1.)

• Remove the rear wheel. (Refer to page 5-27.)

• Loosen the carburetor clamp screw

CD.

• Disconnect the crankcase breather hose @.

• Remove the air cleaner by removing the mounting bolts @.

• Disconnect the brake hose from the hose guides.

• Remove the drive chain cover and guide.

• Remove the rear shock absorber lower mounting bolt @.

• Remove the cushion lever mounting nut

® and bolt.

CHASSIS 5·40

5·41 CHASSIS

• Remove the rear swing arm pivot nut after removing the caps.

• Remove the rear swingarm by removing the pivot shaft.

• Remove the rear shock absorber.

• Remove the cushion rods with cushion lever. >

• Remove the drive chain buffer.

• Remove the brake hose guides and mud guard.

• Remove the cushion rods.

• Remove the swingarm dust seals and spacers.

• Remove the cushion lever dust seals and spacers. o

INSPECTION AND DISASSEMBLY

SWINGARM

Inspect the swingarm for wear or damage.

Inspect the spacer for any flaws or other damage.

Insert the spacer into the bearing and check the play to move the spacer up and down.

If an excessive play is noted, replace the bearing with a new one.

• Draw out the swingarm bearings and spacer with the special tools.

S

09923-74510: Bearing remover

09930-30102: Sliding shaft

IA

CAUTION

I

The romoved bearings should be replaced with new ones.

CHASSIS 5-42

5·43 CHASSIS

CUSHION LEVER

Inspect the spacer for any flaws or other damage.

Insert the spacer into the bearing and check the play to move the spacer up and down. If an excessive play is noted, replace the bearing with new ones.

• Draw out the bearing with the special tools and appropriate tool. sm

09923-73210: Bearing remover

09930-30102: Sliding shaft

I

A

CAUTION I

The removed bearing should be replaced with new ones.

SHOCK ABSORBER

Inspect the shock absorber for oil leakage or other damage.

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

SWINGARM PIVOT SHAFT

Using a dial gauge, check the pivot shaft runout and replace it if the runout exceeds the limit.

BIb

09900-20606: Dial gauge

09900-20701: Magnetic stand

09900-21304: V-block

Service Limit: 0.3 mm (0.01 in)

REASSEMBLY AND REMOUNTING

Reassemble and remount the rear swingarm and suspension in the reverse order of removal and disassembly. Payattention to the following points:

SWINGARM BEARING

• Install the new bearing with the special tool.

Bm

09941-34513: Bearing installer

NOTE:

When installing the bearing, punch-marked side of bearing faces outside.

CUSHION LEVER BEARING

• Install the new bearing with the special tool.

,·&11

09924-84521: Bearing installer

NOTE:

When installing the bearing, punch-mark side of bearing faces outside.

• Remount the rear suspension. (Refer to page 5-45.)

CHASSIS 5·44

5-45 CHASSIS

REASSEMBLING INFORMATION

Left'" "'Right

®--+III

DhT;=~rr=1

@--+-If-.

~~)'{j'"--+l-+--© r--

Ii?-r

~

IF

~

ITEM N-m kg-m Ib-ft

@ 55 5.5 40.0

® 55 5.5 40.0

©

100 10.0 72.5

©

80 8.0 58.0

® 100 10.0 72.5

®

77 7.7 55.5

-++-+-I~

~~~~-p

J i1SJ

~~

FINAL INSPECTION AND ADJUSTMENT

After installing the rear suspension and wheel, the following adjustments are required before driving.

* Drive chain ........................................... Page 2- 9.

* Rear brake pedal height .......................... Page 2-11.

* Tire pressure ......................................... Page 2-13.

SHOCK ABSORBER SPRING PRE-LOAD

ADJUSTMENT

Spring pre-load is adjustable by changing the spring adjuster ring position after removing the shock absorber. Turning the spring adjuster ring counterclockwise or clockwise as viewed from for increase or decrease the spring pre-load after loosening the adjuster lock ring. The standard set length is

247.5 mm.

After adjusting the pre-load, tighten the spring adjuster lock ring securely.

~

Universal clamp wrench

IA

CAUTION

I

Do not set the spring to the length less than 238.5 mm

(9.4 in).

SPRING SETTING TABLE

--------

Spring pre-set length

Softest

Standard

253.5 mm (10.0 in)

247.5 mm (9.7 in)

Stiffest 238.5 mm (9.4 in)

SHOCK ABSORBER DAMPING FORCE ADJUSTMENT

Fully turn the damping force adjuster clockwise. It is at stiffest position and turn it out to the standard setting position.

STD position: 8 clicks turns out

CHASSIS 5·46

5-47 CHASSIS

LOWERING THE SEAT HEIGHT

The seat height can be lowered 40 mm by changing the location of the inner parts of the front fork and rear shock absorber and replace the optional side stand_

OPTIONAL PARTS SUPPLY

Part No_

Non

Part Name

Side stand

®

(Silver painting)

09248-10006 Plug

42300-32820

62184-32EOO Plate

42300-32810

68380-32E 10 Label set

Non Side stand @ (Silver painting)

09248-10006 Plug

62184-32EOO Plate

68380-32EOO Label set

NOTE:

Side stand length @is defferent from ®in the above chart.

SPECIAL TOOLS

pes

1

1

1

1

1

1

1

1

Note

For E-03

E-24

E-28

E-33

For the others

This special tool is used for loosening and tightening the front fork damper rod bolt.

09940-34520: liT" handle

This special tool is used with tool

(09940-34520) for loosening and tightening the front fork damper rod bolt_

09940-34592: Attachment "G"

This special tool is used for adjusting the front fork oil level.

09943- 7 4111: Front fork oil level gauge

This special tool is used for loosening and tightening the rear shock absorber ring.

09910-60611: Universal clamp wrench

CHASSIS 5·48

FRONT FORK

®~ c

r--------

71

II

!j

@U

/

/

Standard spacer

CD position

Change s acer

CD position

CD

Spacer

@

Wa~her

@ Spring

@ Damper

®

Spring

o

Speedom

®

Front wheel

® spacte~rake caliper

11-'--,...--

®

®

5·49 CHASSIS

REMOVAL AND DISASSEMBLY

• Loosen the front axle holder nuts

CD and axle @.

• Carefully position a jack under the chassis tubes and raise until the front wheel is slightly off the ground.

• Remove the front wheel by removing the axle.

• Remove the front brake caliper mounting bolts @.

• Remove the front brake hose clamp bolt @ and speedometer cable guide bolt @.

• Slightly loosen the front fork cap bolt

® after loosening the front fork upper clamp bolt (j) to facilitate later disassembly.

• Remove the front fork by loosening the lower clamp bolts

®.

• Remove the other side front fork the same way.

• Remove the front fork cap bolt

®, spacer @, washer @ and spring @.

• Invert the front fork and stroke it several times to drain fork oil.

CHASSIS 5·50

• Remove the damper rod bolt with a 8 mm hexagon wrench and special tools .

• ,;oob

09940-34520: "T" handle

09940-34592: Attachment "G"

• Remove the damper rod

CD with spring @.

REASSEMBLY AND REMOUNTING

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

• Install the removed spacer @ and spring @ to the damper rod as shown in the photo.

--frru

w®

• Insert the damper rod assembly to the inner tube with the special tool .

• roob

09940-34520: "T" handle

09940-34592: Attachment "G"

• Apply THREAD LOCK

I I

1342" to the damper rod bolt.

IA

CAUTION

I

Use a new gasket @ to prevent oil leakage.

~

!

THREAD LOCK" 1342"

5·51 CHASSIS

• Tighten the damper rod bolt to the specified torque with a 8 mm hexagon wrench and special tools. t!J

Damper rod bolt: 30 N'm (3.0 kg-m, 21.5 Ib-ft)

'MOb

09940-34520: "T" handle

09940-34592: Attachment "G"

• Pour specified fork oil into the inner tube .

• FORK!

Fork oil type: Fork oil # 1 0

99000-99044-10G: SUZUKI FORK OIL # 10

Capacity (each leg): 563 ml (19.0/19.8 US/Imp oz)

• Hold the front fork vertical and adjust the fork oil level with the special tool.

,gob

09943-74111: Fork oil level gauge

Oil level: 150 mm (5.9 in)

NOTE:

When adjusting the oil level, remove the fork spring and compress the inner tube fully.

• Install the fork spring close pitch side up.

• Install the washer and fork cap bolt, and tighten the cap bolt your hand.

• When remounting the front fork, align the upper surface

CD of the inner tube with the upper surface

0 of the steering stem upper bracket.

Upper~

• Tighten the front fork lower clamp bolts and fork cap bolt to the specified torque.

• Tighten the front fork upper clamp bolt to the specified torque.

Upper clamp bolt : 29 N·m (2.9 kg-m, 21.0 Ib-ft)

Lower clamp bolt : 26 N·m (2.6 kg-m, 19.0 Ib-ft)

• Install the brake hose clamp and speedometer cable guide correctly.

• Tighten the front brake caliper mounting bolts to the specified torque.

(2.6 kg-m, 19.0 Ib-ft)

• Align the drive lugs

CD with the recesses @ of the wheel hub.

• Before tightening the front axle, position the stopper @ of the speedometer gearbox against stopper @.

• Tighten the front axle to the specified torque and then move the front fork up and down.

• Tighten the upper axle holder nuts first and then lower nuts to the specified torque.

Axle holder nut: 10 N·m (1.0 kg-m, 7.0 Ib-ft)

CHASSIS 5·52

5·53 CHASSIS

REAR SHOCK ABSORBER

G) Rear shock absorber

@ Plate (Optional part)

@ Plug (Optional part)

@ Spring seat

Standard spring seat

@

and mounting position

LL--....JA.-~-®

@@---fl:l ®

Changed spring seat

@

and mounting position.

ITEM N·m

® 55

@ 30 kg-m

5.5

3.0

Ib-ft

40.0

21.5

REMOVAL AND DISASSEMBLY

• Remove the right and left frame covers.

• Remove the seat by removing mounting bolts.

• Loosen the carburetor clamp screw

CD.

• Disconnect the crankcase breather hose @.

• Remove the air cleaner by removing mounting bolts @.

CHASSIS 5·54

• Remove the rear shock absorber by removing mounting bolts (@, @).

5-55 CHASSIS

• Loosen the spring pre-load adjuster lock ring and adjuster ring fully with the special tool.

,roOl.

09910-60611: Universal clamp wrench

• Remove the spring seat

CD and plate @ by moving the cushion @ to the shock absorber cylinder side.

NOTE:

The removed plate @ will not be used when reassembling the shock absorber.

REASSEMBLY AND REMOUNTING

Reassemble and remount the rear shock absorber and air cleaner in the reverse order of removal and disassembly. Pay attention to the following points:

• When installing the spring seat

CD to the shock absorber, invert it from standard position.

• Position the cushion @ against washer @.

• Tighten the spring adjuster ring and adjust the spring preload with the special tool. The standard set length is 247.5 mm.

• After adjusting the pre-load, tighten the adjuster lock ring securely.

,-mb

09910-60611: Universal clamp wrench

SPRING SETTING TABLE

-------

Spring pre-set length

Softest

Standard

253.5 mm (10.0 in)

247.5 mm (9.7 in)

238.5 mm (9.4 in) Stiffest

• Tighten the plug

CD

(optional part) to the lower mounting part of shock absorber @ to the specified torque.

• Install the shock absorber lower plate @ (optional part) as shown in the illustration.

• Install the rear shock absorber and tighten it to the specified torque.

(Upper and lower)

SIDE STAND

CHASSIS 5·56

L H - R H

1

CD

CD

CD

Side stand

@ Inner spring

@ Outer spring

ITEM N·m

@

@

50

55 kg-m

5.0

5.5

Ib-ft

36.0

40.0

5-57 CHASSIS

SIDE STAND REMOVAL AND INSTALLATION

• Support the motorcycle with jack or wooden block.

• Remove the original side stand by removing mounting nut and bolt.

• Apply SUZUKI SUPER GREASE" A" to the side stand pivot portion and spring hooks.

• Install the optional shorter side stand (silver-colored) and springs correctly as shown in the illustration.

• Tighten the side stand mounting bolt and nut to the specified torque.

Nut: 55 N-m (5.5 kg-m, 40.0 Ib-ft)

.A

WARNING

A new, shorter, silver-colored optional side stand must be installed for safe parking.

NOTE:

Make sure that the side stand switch operation after installing the side stand.

WARNING LABEL

• Attach the warning label (optional part) to the swingarm as shown in the illustration.

NOTE:

Select the appropriate language label for your country.

Warning label

Tire pressure label

Swingarm left side

6·1 ELECTRICAL SYSTEM

CAUTIONS IN SERVICING

CONNECTOR

• When connecting a connector, be sure to push it in untill a click is felt.

• Inspect the connector for corrosion, contamination and breakage in its cover.

COUPLER

• With a lock type coupler, be sure to release the lock before disconnecting it and push it in fully till the lock works when connecting it.

• When disconnecting the coupler, be sure to hold the coupler itself and do not pull the lead wires.

• Inspect each terminal on the coupler for being loose or bent.

• Inspect each terminal for corrosion and contamination.

CLAMP

• Clamp the wire harness at such positions as indicated in

"WIRE HARNESS ROUTING" (Refer to pages 7-12 and

13.).

• 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.

CORRECT INCORRECT

SEMI-CONDUCTOR EQUIPPED PART

• Be careful not to drop the part with a semi-conductor built in such as a CDI unit and regulator/rectifier.

• When inspecting these parts, follow inspection instruction strictly. Neglecting proper procedure may cause damage to these parts.

BATTERY

• The MF battery used in this vehicle does not require maintenance as inspection of electrolyte level and replenishment of water_

• No hydrogen gas is produced during normal charging of the battery, but such gas may be produced when it is overcharged. Therefore, do not bring fire near the battery while it is being charged.

• Note that the charging system for the MF battery is different from that of an ordinary battery. Do not replace with an ordinary battery.

CONNECTING BATTERY

• When disconnecting terminals from the battery for disassembly or servicing, be sure to disconnect the negative (

8 ) terminal first.

• When connecting terminals to the battery, be sure to connect the positive ( @ ) terminal first.

• If the terminal is found corroded, remove the battery, pour warm water over it and clean with a wire brush.

• Upon completion of connection, apply grease lightly.

• Put a cover over the positive ( @ ) terminal.

ELECTRICAL SYSTEM 6-2

WIRING PROCEDURE

• Route the wire harness properly according to "WIRE HAR-

NESS ROUTING" (Refer to pages 7-12 and 13.).

USING POCKET TESTER

• Be sure to use positive ( @ ) and negative (

8 ) probes of the tester properly. Their false use may cause damage in the tester.

• If the voltage and current values are not known, start measuring in the higher range.

• Before measuring the resistance and after changing the resistance range, always perform 0 Q adjustment.

• Taking a measurement where voltage is applied in the resistance range may cause damage in the tester. When measuring resistance, check to make sure that no voltage is applied there.

• After using the tester, turn the switch to the OFF position.

Adjuster

6-3 ELECTRICAL SYSTEM

LOCATION OF ELECTRICAL COMPONENTS

CD

Battery

@ Fuse

@ Starter relay

®

Generator

®

Ignition coil

®

Starter motor o

Horn

®

COl unit

®

Diode

®

Turn signal relay

@ Regulator!rectifier

@ Side-stand/ignition interlock relay

@ Side-stand switch

ELECTRICAL SYSTEM 6-4

CHARGING SYSTEM

DESCRIPTION

The circuit of the charging system is indicated in the figure, which is composed of an AC generator, regulator/rectifier unit and battery_

The AC current generated from AC generator is converted by rectifier and is turned into DC current, then it charges the battery_

r---------------------,

Ignition switch

AC generator

SCR SCR SCR

~

I

I

: Battery

-'o

« o

...J

~----------------------

Regulator /rectifier

/ /

6·5 ElECTRICAL SYSTEM

TROUBLESHOOTING

Battery runs down quickly.

I

Check accessories which excessively waste electric power.

I - -

Installed

~.

Remove accessories.

I

Not installed

Inspect battery leak current. 1---_ _ _

----l.~.

Short circuit of wire harness.

(Refer to page 6-6.)

•

• Loose or disconnected wires.

•

Faulty battery.

I

No leak

•

Inspect charging voltage between battery terminals. f - - - - ~. Faulty battery.

(Refer to page 6-6.) • Abnormal driving condition.

I

Incorrect

•

Inspect continuity generator

1 - - - - -

No coils. (Refer to page 6-7.) continuity---l.~

• Faulty generator coils or disconnected lead wires.

I

Correct

•

Inspect generator no-load voltage. (Refer to page 6-7.) f----Incorrect----l.~.

Faulty generator rotor.

I

Correct

•

Inspect regulator/rectifier.

(Refer to page 6-8.)

I

Correct

•

Inspect wirings. I-----Incorrect----l.~ • Short circuit of wire harness.

• Poor contact of couplers.

I

Correct

IL----------------l.~.

Faulty battery.

( Others)

Battery overcharge • Faulty regulator/rectifier

• Faulty battery

• Poor contact of generator lead wire coupler

ELECTRICAL SYSTEM 6-6

INSPECTION

BATTERY LEAK CURRENT INSPECTION

• Remove the frame covers and seat_

• Remove the battery holder plate

CD .

• Turn the ignition switch to the OFF position.

• Disconnect the battery

8 lead wire.

Note that leakage is indicated if the needle swings even a little when the miliiampare meter of the pocket tester is connected between a

8 terminal and the lead wire of the battery as shown.

'Mob

09900-25002: Pocket tester

IA

CAUTION

I

• Because the leak current might be large, turn the tester to high range first when connecting an ammeter.

• Do not turn the ignition switch to the ON position when measuring current_

When leakage is found, look for the part where the needle does not swing through the couplers and connectors are removed one by one.

CHARGING OUTPUT INSPECTION

• Remove the frame covers and seat.

• Remove the battery holder plate.

• Start the engine and keep it running at 5000 r/min. with lighting switch turned ON and dimmer switch turned HI position.

Measure the DC voltage between the battery terminals (jj and

8 with a pocket tester. If the tester reads under the specified value, inspect the generator coil and regulator/rectifier.

IA

CAUTION

I

If the pocket tester is set to read current or resistance and a voltage is applied across the test probes, damage will result. Therefore, it is important that the tester knob on the pocket tester be set the proper position before making any measurements.

NOTE:

When making this test, be sure that the battery is fullycharged condition.

,·g;lI

09900-25002: Pocket tester

~Tester knob indication: DC 25V

Charging output

Standard: 13.0-16.0 at 5 000 r/min.

8

Battery I ffi

-----,,...---t:

1- - -- ---I II----.--

J

- -

-

(DCV)

Tester

6-7 ELECTRICAL SYSTEM

GENERATOR COIL CONTINUITY INSPECTION

• Remove the frame covers and seat_

• Disconnect the generator lead wire coupler

CD.

Using a pocket tester, inspect the continuity between the three lead wires.

If there is no continuity, replace the generator coil with a new one .

• MOlt

09900-25002: Pocket tester

~Tester knob indication: X Hl range

GENERATOR NO-LOAD PERFORMANCE INSPECTION

• Remove the frame covers and seat.

• Disconnect the generator lead wire coupler

CD .

• Start the engine and keep it running at 5 000 r/min.

Using a pocket tester, measure the voltage between the three lead wires.

If the tester reads under the specified value, replace the generator coil with a new one.

Eib

09900-25002: Pocket tester

Generator no-load performance:

More than 75V/5 000 r/min

(When engine is cold)

REGULATORIRECTIFIER INSPECTION

• Remove the right frame cover.

• Disconnect the regulator/rectifier coupler

CD.

Using a pocket tester ( x 1 kQ range), measure the resistance between the terminals in the following table.

If resistance is incorrect, replace the regulator/rectifier.

,roOl.

09900-25002: Pocket tester

~Tester knob indication: X 1kQ range

Unit: kG

'\

Q)

-

0

..,

<J)

..,

------

8

Y1

.0

0 c: Y2

CD Y3

00:

Infinity

(±)

--------

1-10

1-10

1-10

(±) Probe of tester to:

8 Y1

00 00

------

00

00

1-10

------

00

Y2

00

1-10

00

Y3

00

1-10

00

00

------

NOTE:

As diodes, thyristors are used inside this regulator/rectifier, the resistance values will differ when an ohmmeter other than the SUZUKI pocket tester is used.

ELECTRICAL SYSTEM 6·8

6·9 ELECTRICAL SYSTEM

STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK

SYSTEM

STARTER SYSTEM DESCRIPTION

The starter system is shown in the diagram below: namely, the starter motor, starter relay, side-stand relay, side-stand switch, neutral switch, clutch lever position switch, starter switch, engine stop switch, IG switch and battery.

Depressing the starter switch (on the right handlebars switch box) energizes the relay, causing the contact points to close which connects the starter motor to the battery. The motor draws about

70 amperes to start the engine.

Starter relay

Side-stand Clutch lever Starter Engine stop relay position switch switch

0 - - - - - 1 - 0

~~:.c;;

Diode

Ignition switch

Neutral switch

SIDE-STAND/IGNITION INTERLOCK SYSTEM DESCRIPTION

This side-stand/ignition interlock system is to prevent starting the motorcycle with the side-stand left down. The system is operated by an electric circuit provided between the battery and ignition coil.

To COl and ignition coil

~ tarter

Clutch lever switch position switch

...r:::::L~

- -.. Side-stand relay

Fuse

Starter relay Starter motor

R

--L

T

Battery

-'-

Neutral indicator light

~;

I

BI

~

? switch 1

B/W

/ i

WIRE COLOR

R : Red

G : Green

BI : Blue

BIW : Black with White tracer

BIIB : Blue with Black tracer

0 : Orange

YIB : Yellow with Black tracer

YB

ELECTRICAL SYSTEM 6·10

The circuit consists of relay, lamp, diode and switches and decides to live the ignition coil depending on the position of the TRANSMISSION and SIDE-STAND with the neutral and side-stand switches working mutually.

The ignition coil lives only in two situations as follows.

1. Transmission: "NEUTRAL (ON)" Side-stand: "DOWN (OFF)"

The current flow @turns "ON" the relay and the ignition coil lives even the side-stand is kept down. This is or warming up the engine.

To CDI and ignition coil

Engine Starter Clutch lever stop switch position switch S'd

~S(JW_it-cC::>h

___

-on~ d I

Ie-stan re ay

Ignition switch

I / " / Neutral

I

-- indicator

\~ light

- - + - @

"ON"

Side-stand switch

Side-stand

"DOWN POSITION"

2. Side-stand: "UP-RIGHT (ON)"

The current flow

® turns "ON" the relay and the ignition coil lives. The engine can be easily started at any transmission position.

Side-stand relay

Ignition switch

Neutral indicator light

@ switch

"OFF"

Side-stand switch

Side-stand

"UP-RIGHT POSITION"

6·11 ELECTRICAL SYSTEM

TROUBLESHOOTING

Starter motor will not run.

The transmission is in neutral.

Turn on the ignition switch with the engine stop switch in "RUN" position.

Check whether to hear the click noise from the starter relay when the starter button is pushed. f - - - - -

Check whether to run the starter motor when connect the starter motor terminal to the

Clicks ----:J~ battery 8) terminal directly.

(Do not use thin wire, because a large amount of current flows.)

No click

I

Run

I

Not run

~

• Faulty starter motor 1

• Faulty starter relay

• Loosen or disconnected starter motor lead wire

Measure the starter relay voltage at the starter relay connectors

(between Y /G 8) and B/W

8) when the starter button is pushed.

-

I

Voltage measured

Not voltage---:J.~. Faulty ignition switch

• Faulty engine stop switch

• Faulty neutral switch

• Faulty diode

• Faulty side-stand relay

• Faulty starter button

• Faulty clutch lever position switch

• Poor contact of connector

• Open circuit in wiring harness 1

Check the starter relay.

(Refer to page 6-14.)

I--Incorrect----l.~· Faulty starter relay

I

Correct

Poor contact of the starter relay

Starter motor runs when the transmission is in neutral, but does not run with the transmission in any position except neutral, with the side-stand up position.

Check the side-stand switch.

(Refer to page 6-16.)

I--Incorrect------J.~· Faulty side-stand switch

I

Correct

L [

----------------~

• •

Open circuit in wiring harness

• Poor contact of connector

( Others)

Engine does not turn though starter motor runs.

• Faulty starter clutch

STARTER MOTOR REMOVAL AND

DISASSEMBL Y

• Remove the exhaust pipe.

• Remove the cam drive chain tensioner.

• Disconnect the starter motor lead wire and remove the starter motor by removing the mounting bolts.

(Refer to page 3-11.)

• Disassemble the starter motor as shown in the illustration.

@

@

@

®

®

®

ELECTRICAL SYSTEM 6·12

®

®

5

CD

O-ring

@ Housing end (inside)

@ Washer set

@ O-ring (2 pes)

®

Starter motor ease

®

Armature

(j) Washer set

@ Brush holder

®

Brush spring

@ Housing end (outside)

STARTER MOTOR INSPECTION

CARBON BRUSH

Inspect the brushed for abnormal wear, crack or smoothness in the brush holder.

If the brush has failed, replace the brush sub assy.

6-13 ELECTRICAL SYSTEM

COMMUTATOR

Inspect the commutator for discoloration, abnormal wear or undercut @ .

If the commutator is abnormally worn, replace the armature.

When surface is descolored, polish it with # 400 sand paper and clean it with dry cloth.

If there is no undercut, scrape out the insulator G) with saw blade.

ARMATURE COIL INSPECTION

Check for continuity between each segment.

Check for continuity between each segment and the armature shaft.

If there is no continuity between the segments or there is continuity between the segments and shaft, replace the armature with a new one.

OIL SEAL INSPECTION

Check the seal lip for damage or leakage.

If any damage is found, replace the bracket.

Segment

STARTER MOTOR REASSEMBLY

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

I

A

CAUTION I

Replace the O-rings with new ones to prevent oil leakage and moisture.

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

~

A"

• Apply a small quantity of MOLY PASTE to the armature shaft.

~99000-25140:

SUZUKI MOLY PASTE

• Apply a small quantity of THREAD LOCK J/1 342J/ to the starter motor housing bolts.

ELECTRICAL SYSTEM 6·14

STARTER RELAY INSPECTION

• Remove the right frame cover.

• Remove the starter relay cover.

• Disconnect the starter motor lead wire and battery lead wire at the starter relay.

• Disconnect the lead wire coupler from the starter relay.

Apply 12 volts to

CD and @ terminals, inspect the continuity between the terminals, positive and negative.

If the starter relay is in sound condition, continuity is found.

,roOl,

09900-25002: Pocket tester

~Tester knob indication: X 10 range

111. CAUTION 1

Do not apply a battery voltage more than 5 seconds to the starter relay as it may overheat and cause damage to the relay coil.

Check the coil for "open", "ground" and ohmic resistance.

The coil is in good condition if the resistance is as follows.

,roOl,

09900-25002: Pocket tester

~Tester knob indication: X 10 range

Starter relay resistance

Standard: 3 - 50

6·15 ELECTRICAL SYSTEM

STARTER RELAY CIRCUIT

DIAGRAM

To starter motor

8

(f) To battery

L .. _

SIDE-STAND/IGNITION INTERLOCK SYSTEM

INSPECTION

If the interlock system does not operate properly, check each component. If any abnormality is found, replace the component with a new one .

• @'u 09900-25002: Pocket tester

DIODE

The diode is located under the seat.

The diode can pass current only in one direction.

Check the continuity between

CD and @ . If one way continuity the diode is in good condition.

Also check the continuity between @ and @ as required.

NEUTRAL SWITCH

The neutral lead wire coupler is located behind the left frame cover.

• Remove the frame covers and seat.

• Disconnect the neutral switch lead and check the continuity between Blue and Ground with the transmission in "NEUTRAL".

SIDE-STAND SWITCH

~ Black/White

(8

Proboe) (@ Proboe)

ON

(UP-right position)

OFF

(Down position)

SIDE-STAND/IGNITION INTERLOCK RELAY

The side-stand/ignition interlock relay is located under the seat.

• Remove the frame covers and seat.

First, check the insulation between

CD and @ terminals with pocket tester. Then apply 12 volts to @ and @ terminals,

@ to @ and

8 to @ , and check the continuity between

CD and @ .

If there is no continuity, replace it with a new one .

• @u09900-25002: Pocket tester

n

range

CLUTCH LEVER POSITION SWITCH

~

Yellow/Green

ON

(Squeeze)

OFF

ELECTRICAL SYSTEM 6·16

®

6-17 ELECTRICAL SYSTEM

IGNITION SYSTEM

DESCRIPTION

In the capacitor discharged ignition system, the electrical energy generated by the magneto charges the capacitor. This energy is released in a single surge at the specified ignition timing point, and current flows through the primary side of the ignition coil. A high voltage current is induced in the secondary windings of the ignition coil resulting in strong spark between the spark plug gap.

BW

Neutral indicator light

Regulator/ rectifier

R

Ignition switch

Engine stop switch o--o-~-__<r o---+-O/W

Lg

, - - - - - - - - - ; - - B / W

Ignition coil

COl unit

CD :

Pick-up coil

@ : Power source coil

@ : Neutral switch

/

-

,

: Battery

-'-

I

P

IU

Spark 9'11

/

Side-stand switch

I

WIRE COLOR

B Black

W

G

BI

White

Green

Blue o

R

Lg

O/W:

B/W:

W/BI:

Orange

Red

Light green

Orange with White tracer

Black with White tracer

White with Blue tracer

ELECTRICAL SYSTEM 6·18

TROUBLESHOOTING

No spark at plugs

* Check that the transmission is in neutral position and the engine stop switch is in the RUN position. Inspect that the fuse is not blown before the diagnosis.

Check the COl couplers for poor contact.

Looseness----:l.~· Poor contact of coupler

I

Correct t

Inspect the battery voltage between input lead wires (O/W and B/W) at the

COl unit with the ignition switch "ON" position.

I

Correct t

Inspect the resistance of pick-up coil (BI and G) and power source coil (B and

W). (Refer to page 6-20.)

-Incorrect---;.~· Faulty ignition switch

• Faulty side-stand relay

• Faulty engine stop switch

• Broken wire harness or poor contact of related circuit connecters

-Incorrect---l.~. Faulty pick-up coil

• Faulty power source coil

I

Correct

-. . . . . . . .

Faulty COl

• Faulty ignition coil

* If only one spark plug does not spark, it is defective or high-tension cord is disconnected because one ignition coil furnishes two spark plugs.

6·19 ELECTRICAL SYSTEM

INSPECTION

IGNITION COIL (Checking with Electro Tester)

• Remove the fuel tank.

• Remove the ignition coil.

NOTE:

Make sure that the three-needle sparking distance of electro tester is set at 8 mm (0.3 in).

With the tester and jumper wire, test the ignition coil for sparking performance in accordance with the following two steps.

STEP

CD :

Connect the jumper wire to the spark plug cap and ignition coil ground.

STEP @ : Switch over the jumper wire to the other plug cap and ground.

If no sparking or orange color sparking occures in the above conditions, it may be caused by defective coil.

,·gb

09900-28107: Electro tester

Spark performance: Over 8 mm (0.3 in)

AWARNING

Do not touch the wire clips to prevent an electric shock when testing.

Jumper

Electro

[0

0

~I tester

1

0

~...

. ~ -~~c-,;.~

CDi

8 mm

-~~

Spark

~

IGNITION COIL (Checking with Pocket Tester)

A SUZUKI pocket tester or an ohm meter may be used, instead of the electro tester. In either case, the ignition coil is to be checked for continuity in both primary and secondary windings. Exact ohmic readings are not necessary, but, if the windings are in sound condition, their continuity will be noted with these approximate ohmic values.

'MOl,

09900-25002: Pocket tester

Ignition coil resistance

Primary: 0.07 - 0.120 (@ Black lead

-8

Black/white lead)

~Tester knob indication: X 10 range

Secondary: 23-25 kO (Plug cap-Plug cap)

ELECTRICAL SYSTEM 6·20

POWER SOURCE COIL AND PICK-UP COIL

• Remove the frame covers and seat.

• Disconnect the lead wire coupler

CD from the CDI unit.

Measure each coil resistance between lead wires. If the resistance is infinity or less than the specifications, the power source coil and pick-up coil must be replaced.

,gill

09900-25002: Pocket tester

Power source coil resistance: 0.1-0.2Q

(Black-White)

~Tester knob indication: X 1Q range

Pick-up coil resistance: 170-256Q

(Blue-Green)

~Tester knob indication: X 100Q range

COl UNIT

• Remove the frame covers and seat.

• Disconnect the lead wire couplers @ from the CDI unit.

Measure the CDI unit resistance between the terminals. If the resistance is incorrect, the CDI unit must be replaced.

NOTE:

As capacitor, thyristors, diodes, etc. are used inside this CDI unit, the resistance values will differ when an ohmmeter other than SUZUKI pocket tester is used.

,Pooh

09900-25002: Pocket tester

Unit: kfl r±l

Probe of tester

-

""

6

1 2 3

2.8-12 2.8-12 8-35

4

17-70

5

3-13

6 7 8 9 10 11 12

~

....

Cfl

....

0

-------

2

3

4

5

0

-------

-------

6-26 12-50 2.4-10 2.6-12

5.5-24 12-50 2.4-10 2.6-12

0

0

~

8-35 8-35 5.5-24

15-70 15-70 26-150 16-70 17-80 5.5-70

2.2-9.5 2.2-9.5 8-35

-------

2.8-12

0 0 6-26

-------

6-26 12-50 2.2-9.5 2.6-11 0 0 0

0

0

50-400 200-00 35-400 1.2-5

50-400 200-00 35-500 1.2-5

5.5-24 50-400 200-00 45-500 7-28

5.5-70 80-500 200-00 80-00 14-60

2.2-9.5 50-400 200-00 40-500 1.4-6

2.8-12 50-400 200-00 40-500 1.8-8

50-400 200-00 35-500 1.2-4.8 <ll

..CI

0

7 ct 8

CD

9 1.8-7.5 1.8-7.5 10-45 24-200 5-22 6-24 1.8-7.5

10 11-50 11-50 22-100 35-400 17-70 17-70 11-50

11

12

00 00 00 00 00 00 00

1.2-5 1.2-5 7-28 14-60 1.4-6 1.8-8 1.2-5

00

50-400 200-00 70-500 3.6-4.8

-------

-------

00

200-00 70-00 3.6-11

200-00 14-60

-------

-------

00

-------

NOTE: When the capacitor is discharged state, the needle of tester swings first then return to a certain value.

00 :

Infinity

6·21 ELECTRICAL SYSTEM

SPARK PLUG

• Remove the spark plugs.

am

09930-10121: Spark plug socket wrench set

Carbon Deposit

Check to see the carbon deposit on the plug.

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

Spark Plug Gap

Measure the plug gap with a thickness gauge if it is correct.

If not, adjust it to the following gap.

,gOt!

09900-20803: Thickness gauge

Standard: 0.7-0.8 mm (0.028-0.031 in)

Electrode's Condition

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

Heat Range

NGK CR1 OE or NIPPONDENSO U31 ESR-N should be used as the standard. However, the heat range of the spark plug should be selected to meet the requirements of speed, actualload, fuel and etc. Proper heat range would be indicated if all insulators were LIGHT BROWN in color. If they are blackened by carbon, they should be replaced with a hot type plug NGK CR9E or NIPPONDENSO U27ESR-N.

--------

Standard Hot type

NGK CR10E CR9E

NIPPONDENSO U31 ESR-N U27ESR-N

! ACAUTION!

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

1

(0.028-0.031 in)

SPEEDOMETER AND PILOT INDICATOR

REMOVAL AND DISASSEMBLY

• Remove the speedometer and pilot indicator. (Refer to page 5-4.)

• Disassemble the speedometer and pilot indicator as follows.

ELECTRICAL SYSTEM 6-22

INSPECTION

Using the pocket tester, check the continuity between lead wires in the diagram on next page.

If the continuity measured is incorrect, replace the respective parts.

,mob

09900-25002: Pocket tester

~Tester knob indication: X 1Q range

NOTE:

When making this test, it is not necessary to remove the speedometer and pilot indicator.

6-23 ELECTRICAL SYSTEM

B/W: ILLUMINATION

8

Gr : ILLUMINATION @

B/W : HIGH BEAM

8

BIBI : NEUTRAL

8

BIR : HIGH BEAM @

BIO : NEUTRAL @

BILg : TURN (R) @

ITEM

ILLUMI

HIGH BEAM

NEUTRAL

TURN (L)

TURN (R)

c±l

Probe of tester to:

Gr

B/R

B/O

B

B/Lg

8

Probe of tester to:

B/W

B/W

BIB I

B/Lg

B

B : Black

Gr : Gray

BIBI : Black with Blue tracer

BIO : Black with Orange tracer

BIR : Black with Red tracer

B/Lg: Black with Light green tracer

B/W : Black with White tracer

LAMPS

HEADLIGHT

Headlight bulb: 12V 60/SSW

Position light bulb: 12V 4W (Except E-03,24,28,33)

NOTE:

Adjust the headlight, both vertical and horizontal, after reassembling_

BULB REPLACEMENT

• Remove the headlight. (Refer to page 5-21.)

• Disconnect the socket

CD and remove the rubber cap @.

• Remove the bulb @ by unlocking the bulb holder spring @.

• Reassemble the bulb in the reverse order of removal.

I

A

CAUTION I

When replacing the headlight bulb, do not touch the glass_ Grasp the new bulb with a clean cloth. If you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol or soapy water to prevent early failure_

ELECTRICAL SYSTEM 6-24

6·25 ELECTRICAL SYSTEM

TAIL/BRAKE LIGHT, TURN SIGNAL LIGHT AND LICENSE PLATE LIGHT

Tail/Brake light bulb: 12V 5/21W

Turn signal light bulb: 1 2V 21 W

License plate light bulb: 12V 5W

BULB REPLACEMENT

• Remove each light lens.

• Push in on the bulb, turn it to the left, and pull it out.

I

A CAUTION

I

Do not overtighten the lens fitting screws.

ELECTRICAL SYSTEM 6-26

TURN SIGNAL RELAY

The turn signal relay Q) is located under the seat.

If the turn signal light does not light. Inspect the bulb or repair the circuit connection.

If the bulb and circuit connection checked are correct, the turn signal relay may be faulty, replace it with a new one.

NOTE:

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

SWITCHES

Inspect each switch for continuity with the pocket tester. If any abnormality is found, replace the respective switch assemblies with new ones .

• Mob

09900-25002: Pocket tester

~Tester knob indication: X 1Q range

IGNITION SWITCH

OFF

ON

LOCK

0 OIY B/W Gr Br

0--0 0--0 0~

STARTER BUTTON

~

•

PUSH 0

P 0 {)

LIGHTING SWITCH

~

OFF

•

ON

0

0

Gr

{)

Y/W

{)

HORN BUTTON

~r

B/BI

•

PUSH 0

FRONT BRAKE SWITCH

0

DIMMER SWITCH

W Y

OFF

ON 0

HI

LO

0

0 {)

{) REAR BRAKE SWITCH

0

TURN SIGNAL SWITCH

~

L

Lbl

0

PUSH

R 0 {)

PASSING LIGHT SWITCH

~

•

PUSH 0

ENGINE STOP SWITCH

OFF

RUN

0

0

Y

{)

{)

B

{)

O/W

OFF

ON 0

Y/G

{)

B/W

{)

B

{)

W/B

-0

WIRE COLOR

B : Black Lbl: Light blue R : Red

Br: Brown Lg: Light green Y: Yellow

Gr: Gray 0 : Orange W: White

B/BI : Black with Blue tracer

B/W: Black with White tracer

O/BI: Orange with Blue tracer

O/R : Orange with Red tracer

O/W: Orange with White tracer

O/Y : Orange with Yellow tracer

W /B: White with Black tracer

Y/G : Yellow with Green tracer

Y/W: Yellow with White tracer

6-27 ELECTRICAL SYSTEM

BATTERY

SPECIFICATIONS

Type designation

Capacity

Standard electrolyte

S.G.

YTX9-BS

12V, 28.8 kC (8 Ah)/1 OHR

1.320 at 20°C (68°F)

INITIAL CHARGING

Filling electrolyte

• Remove the aluminum tape

CD sealing the battery electrolyte filler holes.

Cathode plates

Filter

Filler holes

• Remove the caps @ .

NOTE:

* After filling the electrolyte completely, use the removed cap @ as the sealed caps of battery-filler holes.

* Do not remove or pierce the sealed areas @ 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.

Electroyte containers

Insert in filler holes

• Make sure air bubbles are coming up each electrolyte container, and leave in this position for about more than 20 minutes.

~

Air bubbles-

-

° °0

00

V o

°0

0 0

0 f0~

pg

0

-

°o

°0

0

0

\-.ll..

00

0

0 0

0-

00

°

~

00 °

°0

0 0 0 0

°0 0

0

00

101 ~

00

0

~

00

00

IfOl

I

I

NOTE:

If no air bubbles are coming up from a filler port, tap the bottom of the two or three times.

Never remove the container from the battery.

ELECTRICAL SYSTEM 6·28

,

,

..

• After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the battery. Wait for around 20 minutes.

• Insert the caps into the filler holes, pressing in firmly so that the top of the caps do not protrude above the upper surface of the battery's top cover.

I

A

CAUTION I

*

Never use anything except the specified battery.

*

Once install the caps to the battery; do not remove the caps.

• Using SUZUKI pocket tester, measure the battery voltage.

The tester should indicate more than 12.5-12.6V (DC) as shown in the Fig. If the battery voltage is lower than the specification, charge the battery with a battery charger. (Refer to the recharging operation.)

NOTE:

Initial charging for a new battery is recommended if two years have elapsed since the date of manufacture.

(V)

~

12

11

10

(at 25°C)

0 2 4 6

Time

8 10 (Minutes)

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.

6·29 ELECTRICAL SYSTEM

RECHARGING OPERATION

• Using the pocket tester, check the battery voltage. If the voltage reading is less than the 12.0V (DC), recharge the battery with a battery charger.

I

A CAUTION I

When recharging the battery, remove the battery from the motorcycle.

NOTE:

Do not remove the caps on the battery top while recharging.

Recharging time: 4A for one hour or O.9A for 5 hours

I

A CAUTION I

Be careful not to permit the charging current to exceed

4A at any time.

(V)

Charging period

~

18

17 r---"'1

16

15

14

13

12 o

10 20 30 40 50 60

Time (Minutes)

(V)

14+--'--.-~r-~--~

10r--r--+---r--+--~

100 75 50 25 0(%)

Battery charged condition

• After recharging, wait for more than 30 minutes and check the battery voltage with a pocket tester.

• If the battery voltage is less than the 12. 5V, recharge the battery again.

• If battery voltage is still less than 12.5V, after recharging, replace the battery with a new one.

• When the motorcycle is not used for a long period, check the battery every 1 month to prevent the battery discharge.

7-1 SERVICING INFORMATION

TROUBLESHOOTING

ENGINE

Complaint Symptom and possible causes

Engine will not start, Compression too low or is hard to start. 1. Out of adjustment valve clearance.

2. Worn valve guides or poor seating of valves.

3. Mistiming valves.

4. Excessively worn piston rings.

5. Worn-down cylinder bores.

6. Too slowly starter motor cranks.

7. Poor seating of spark plugs.

Plugs not sparking

1. Fouled spark plugs.

2. Wet spark plugs.

3. Defective ignition coil.

4. Open or short in high-tension cords.

5. Defective generator or CDI unit.

6. Defective side stand switch or side stand relay.

No fuel reaching the carburetor

1. Clogged fuel tank cap.

2. Clogged or defective fuel valve.

3. Defective carburetor needle valve.

4. Clogged fuel hose or vacuum hose.

5. Clogged fuel filter.

Engine stalls easily.

Noisy engine.

1. Fouled spark plugs.

2. Defective signal generator or CDI unit.

3. Clogged fuel hose.

4. Clogged jets in carburetor.

5. Out of adjustment valve clearance.

Excessive valve chatter

1. Too large valve clearance.

2. Weakened or broken valve springs.

3. Worn down rocker arm or rocker arm shaft.

4. Worn and burnt camshaft journal.

Noise seems to come from piston

1. Worn down piston or cylinder.

2. Fouled with carbon combustion chamber.

3. Worn piston pins or piston pin bore.

4. Worn piston rings or ring grooves.

Noise seems to come from timing chain

1. Stretched chain.

2. Worn sprocket.

3. Not working tension adjuster.

Noise seems to come from clutch

1. Worn splines of countershaft or hub.

2. Worn· teeth of clutch plates.

3. Distorted clutch plates, driven and drive.

4. Worn clutch release bearing.

5. Weakened clutch dampers.

Remedy

Adjust.

Repair or replace.

Adjust.

Replace.

Replace or rebore.

See electrical section.

Retighten.

Clean.

Clean and dry.

Replace.

Replace.

Replace.

Replace.

Clean or replace.

Clean or replace.

Replace.

Clean or replace.

Clean or replace.

Clean.

Replace.

Clean.

Clean.

Adjust.

Adjust.

Replace.

Replace.

Replace.

Replace.

Clean.

Replace.

Replace.

Replace.

Replace.

Repair or replace.

Replace.

Replace.

Replace.

Replace.

Replace the primary driven gear.

SERVICING INFORMATION 7-2

Complaint

Noisy engine.

Slipping clutch.

Dragging clutch.

Transmission not shift.

Transmission will will not shift back.

Transmission jumps out of gear.

Engine idles poorly.

Symptom and possible causes

Noise seems to come from crankshaft

1. Due to wear rattling bearings.

2. Worn and burnt big-end bearings.

3. Too large thrust clearance.

Noise seems to come from transmission

1. Worn or rubbing gears.

2. Badly worn splines.

3. Worn or rubbing primary gears.

4. Badly worn bearings.

1. Out of adjustment or loss of play clutch control.

2. Weakened clutch springs.

3. Worn or distorted pressure plate.

4. Distorted clutch plates, driven and drive.

Remedy

Replace.

Replace.

Replace conrod.

Replace.

Replace.

Replace.

Replace.

Adjust.

Replace.

Replace.

Replace.

1. Clutch control out of adjustment or loss of play. Adjust

2. Some clutch springs weakened while others are not. Replace.

3. Distorted pressure plate or clutch plates. Replace.

1. Broken gearshift cam.

2. Distorted gearshift forks.

3. Worn gearshift pawl.

Replace.

Replace.

Replace.

1. Broken return spring on shift shaft.

2. Rubbing or stickly shift shaft.

3. Distorted or worn gearshift forks.

Replace.

Repair or replace.

Replace.

1. Worn shifting gears on driveshaft or countershaft. Replace.

2. Distorted or worn gearshift forks. Replace.

3. Weakened stopper spring on gearshift cam.

4. Worn gearshift pawl.

Replace.

Replace.

1. Out of adjustment valve clearance.

2. Poor seating of valves.

3. Defective valve guides.

4. Worn rocker arms or arm shafts.

5. Too wide spark plug gaps.

6. Defective ignition coil.

7. Defective generator or CDI unit.

8. Out of adjustment in carburetor float-chamber fuel level.

9. Clogged jets.

Adjust.

Replace or repair.

Replace.

Replace.

Adjust or replace.

Replace.

Replace.

Adjust.

Clean.

7-3 SERVICING INFORMATION

Complaint

Engine runs poorly in high speed range.

Dirty or heavy exhaust smoke.

Symptom and possible causes

1 _ Weakened valve springs.

2. Worn camshafts.

3. Valve timing out of adjustment.

4. Too narrow spark plug gaps.

5. Ignition not advanced sufficiently due to poorly working timing advance circuit.

6. Defective ignition coil.

7. Defective generator or CDI unit.

8. Too low float-chamber fuel level.

9. Clogged air cleaner element.

10. Clogged fuel hose, resulting in inadequate fuel supply to carburetor.

1. Too much engine oil in the engine.

Engine lacks power.

Engine overheats.

2. Worn piston rings or cylinder.

3. Worn valve guides.

4. Scuffed cylinder wall.

5. Worn valves stems.

6. Defective stem seal.

7. Worn oil ring side rails.

1. Loss of valve clearance.

2. Weakened valve springs.

3. Out of adjustment valve timing.

4. Worn piston rings or cylinder.

5. Poor seating of valves.

6. Fouled spark plug.

7. Incorrect spark plug.

8. Clogged jets in carburetor.

9. Out of adjustment float-chamber fuel level.

10. Clogged air cleaner element.

11. Sucking air from intake pipe.

12. Too much engine oil.

13. Diffective generator, CDI unit or ignition coil.

1. Heavy carbon deposit on piston crown.

2. Not enough oil in the engine.

3. Defective oil pump or clogged oil circuit.

4. Too low in float chamber fuel level.

5. Sucking air from intake pipes.

6. Use incorrect engine oil.

7. Oil cooler.

Remedy

Replace.

Replace.

Adjust.

Adjust.

Replace CDI unit.

Replace.

Replace.

Adjust.

Clean.

Clean and prime.

Check with inspection window drain out excess oil.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Adjust.

Replace.

Adjust.

Replace.

Repair.

Clean or replace.

Adjust or replace.

Clean.

Adjust.

Clean.

Retighten or replace.

Drain out excess oil.

Replace.

Clean.

Add oil.

Replace or clean.

Adjust.

Retighten or replace.

Change.

Clean.

SERVICING INFORMATION 7-4

CARBURETOR

Complaint

Trouble with starting.

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 pipe.

3. Air leaking from a joint between starter body and carburetor.

4. Air leaking from carburetor's joint or vacuum gauge joint.

5. Not operation properly starter plunger.

1. Clogged or loose pilot jet, pilot air jet.

2. Air leaking from carburetor's joint, vacuum hose joint, or starter.

3. Clogged pilot outlet or bypass.

4. Not fully closed starter plunger.

1. Clogged main jet or main air jet.

2. Clogged needle jet.

3. Not operating properly throttle valve.

4. Clogged fuel filter.

1. Worn or damaged needle valve.

2. Broken spring in needle valve.

3. Not working properly float.

4. Foreign matter has adhered to needle valve.

5. Too high or low fuel level.

Remedy

Clean.

Clean.

Check starter body and carburetor for tightness, adjust and replace gasket.

Check and adjust.

Check and adjust.

Check and clean.

Check and adjust.

Check and clean.

Check and adjust.

Check and clean.

Check and clean.

Check throttle valve for operation.

Check and clean.

Replace.

Replace.

Check and adjust.

Clean.

Adjust float height.

CHASSIS

Complaint

Heavy steering.

Wobbly handlebars.

Wobby front wheel.

Front suspension too soft.

Front suspension too stiff.

Noisy front suspension.

Symptom and possible causes

1. Overtightened steering stem nut.

2. Broken bearing in steering stem.

3. Distorted steering stem.

4. Not enough pressure in tires.

Remedy

Adjust.

Replace.

Replace.

Adjust.

1. Loss of balance between right and left front forks. Replace.

2. Distorted front fork. Repair or replace.

3. Distorted front axle or crooked tire. Replace.

1. Distorted wheel rim.

2. Worn front wheel bearings.

3. Defective or incorrect tire.

4. Loose axle or axle holder nuts.

5. Incorrect front fork oil level.

1. Weakened springs.

2. Not enough fork oil.

Replace.

Replace.

Replace.

Retighten.

Adjust.

Replace.

Replenish.

1. Too viscous fork oil.

2. Too much fork oil.

1. Not enough fork oil.

2. Loose bolts and nuts on suspension.

Replace.

Drain excess oil.

Replenish.

Retighten.

7-5 SERVICING INFORMATION

Complaint

Wobbly rear wheel.

Rear suspension too soft.

Rear suspension too stiff.

Symptom and possible causes Remedy

1 . Distorted wheel rim.

2. Worn rear wheel bearings or swingarm bearings.

Replace.

Replace.

3. Defective or incorrect tire. Replace.

4. Worn swingarm and rear suspension related bearings. Replace.

5. Loose nuts or bolts on rear suspensions. Retighten.

1. Weakened shock absorber spring.

2. Improperly set rear suspension adjuster.

3. Leakage oil of shock absorber.

Replace.

Adjust.

Replace.

1. Improperly set rear suspension adjuster.

2. Bent shock absorber shaft.

Adjust.

Replace.

3. Bent swingarm. Replace.

4. Worn swingarm and rear suspension related bearings. Replace.

1. Loose nuts or bolts on rear suspension. Retighten.

2. Worn swingarm and rear suspension related bearings. Replace.

Noisy rear suspension.

BRAKES

Complaint

Insufficient brake power.

Brake squeaking.

Symptom and possible causes

1 . Leakage of brake fluid from hydraulic system.

2. Worn pads.

3. Oil adhesion of engaging surface of pads.

4. Worn disc.

5. Air in hydraulic system.

1. Carbon adhesion on pad surface.

2. Tilted pad.

3. Damaged wheel bearing.

4. Loosen front-wheel axle or rear-wheel axle.

5. Worn pads.

6. Foreign material in brake fluid.

7. Clogged return port of master cylinder.

Excessive brake 1. Air in hydraulic system. lever or pedal stroke. 2. Insufficient brake fluid.

3. Improper quality of brake fluid.

Leakage of brake fluid.

1. Insufficient tightening of connection joints.

2. Cracked hose.

3. Worn piston and/or cup.

Remedy

Repair or replace.

Replace.

Clean disc and pads.

Replace.

Bleed air.

Repair surface with sandpaper.

Modify pad fitting or replace.

Replace.

Tighten to specified torque.

Replace.

Replace brake fluid.

Disassemble and clean master cylinder.

Bleed air.

Replenish fluid to specified level; bleed air.

Replace with correct fluid.

Tighten to specified torque.

Replace.

Replace piston and/or cup.

SERVICING INFORMATION 7-6

ELECTRICAL

Complaint

No sparking or poor sparking.

Spark plug soon become fouled with carbon.

Symptom and possible causes

1 _ Defective ignition coil.

2. Defective spark plugs.

3. Defective generator or COl unit.

1. Mixture too rich.

2. Idling speed set too high.

3. Incorrect gasoline.

4. Dirty element in air cleaner.

5. Too cold spark plugs.

Spark plugs become fouled too soon.

Spark plug electrodes overheat or burn.

Generator does not charge.

Generator does charge, but charging rate is below the specification.

Generator overcharges.

1. Worn piston rings.

2. Worn piston or cylinder.

3. Excessive clearance of valve stems in valve guides.

4. Worn stem oil seal.

1. Too hot spark plugs.

2. Overheated the engine.

3. Loose spark plugs.

4. Too lean mixture.

1. Open or short lead wires, or loose lead connections.

2. Shorted, grounded or open generator coils.

3. Shorted or panctured regulator/rectifier.

1. Lead wires tend to get shorted 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.

1. Internal short-circuit in the battery.

2. Damaged or defective regulator/rectifier.

3. Poorly grounded regulator/rectifier.

Unstable charging. 1. Lead wire insulation frayed due to vibration, resulting in intermittent shorting.

2. Internally shorted generator.

3. Defective regulator/rectifier.

Starter button is not 1 . Run down battery. effective. 2. Defective switch contacts.

3. Not seating properly brushes on commutator in starter motor.

4. Defective starter relay/starter interlock switch.

Remedy

Replace.

Replace.

Replace.

Adjust carburetor.

Adjust carburetor.

Change.

Clean.

Replace with hot type plugs.

Replace.

Replace.

Replace.

Replace.

Replace with cold type plugs.

Tune up.

Retighten.

Adjust carburetor.

Repair or replace or retighten.

Replace.

Replace.

Repair or retighten.

Replace.

Replace.

Replace the battery.

Replace the battery.

Replace.

Clean and tighten ground connection.

Repair or replace.

Replace.

Replace.

Repair or replace.

Replace.

Repair or replace.

Replace.

7·7 SERVICING INFORMATION

BATTERY

Complaint

"Sulfation", acidic white powdery substance or spots on surfaces of cell plates.

Battery runs down quickly.

Symptom and possible causes

1. Cracked battery case.

2. Battery has been left in a run-down condition for a long time.

Remedy

Replace the battery.

Replace the battery.

Battery "sulfation".

Battery discharges too rapidly.

1. Not correct the charging system. Check the generator, regulator Irectifier and circuit connections and make necessary adjustments to obtain specified charging operation.

2. Cell plates have lost much of their active material as a result of overcharging.

Replace the battery, and correct the charging system.

3. A short-circuit condition exists within the battery. Replace the battery.

4. Too low battery voltage. Recharge the battery fully.

5. Too old battery. Replace the battery.

Replace the battery. 1. Too low or too high charging rate.

(When not in use batteries should be checked at least once a month to avoid sulfation.)

2. Left unused the battery for too long in cold climate.

Replace the battery, if badly sulfated.

Dirty container top and sides. Clean.

SPEEDOMETER

INDICATOR LIGHT

IEILEINE 522%

SWITCH SWITCH

STARTER

BUTTON

IIEIIEIOI II

REAR BRAKE

EIIE5] swITcH TURN

IE!

EU

IGNITION COIL DIODE H HIGH BEAM INDICATOR LIGHT

N NEUTRAL INDICATOR LIGHT

TURN SIGNAL INDICATOR LIGHT

<3

FRONT TURN SIGNAL LIGHT (RI

B I-9

HEADLIGHT

Y

B/W

W

EEl‘*:]

DEM

B

B/W

B

B/W

FRONT TURN SIGNAL LIGHT (LI

Em

= _

‘£55

HORN BUTTON EI[02{01_

TURN SIGNAL

“G

HT swncn

>§°=T"=§

>-§o=m5‘

E

'”

E

$53?»-§>§

5

3°”

--

2

§§E%%

E

O

O

Y/W

2

>'

“E

O l E m

In

2

In

5

3

2€__fl

_

III i_i—

Ir.

I

I

REAR TURN SIGNAL LIGHT IRI

Lg

B/W

B

TED’ '[@

TAIL/BRAKE LIGHT

Br

BIW

Br

E/W

LICENSE LIGHT

I;?I:lflIa?»J[®

REAR TURN SIGNAL LIGHT ILI

I I

HORN

I:O

DY BW

/-

_

0

_

—

L’)

B

EI-n_

En

" EWIHEET W mm

;

I

DIMME" ---—-NEUTRAL REGULATORI GENERATOR swncu EEEQEEEE LEVER

IGNITION SWITCH

SWITCH RECTIFIER

.

>>>>->-3; mg

FUSE aox

(D: HEADLIGHT IHII ' a/w R

_ g

.

.

STARTER

RE‘-/‘Y

I

3 aw—IflJ R

W

Y

WIRE COLOR

B Black

Bl

Br

Blue

Brown

G

Gr

Lbl

L9

O

Green

Gray

Light blue

Light green

Orange

Red

White

Yellow

B/Lg

~ BATTERY Bro

B/R

B/W

8|/8

Black with Blue tracer

Black with Light green tracer

Black with Orange tracer

Black with Red tracer

Black with White tracer

Blue with Black tracer

F: MAIN FUSE

M: STARTER MOTOR

8|/W :

G/BI

O/W

Blue with White tracer

Green with Blue tracer

Orange with White tracer

O/Y

R/B

W/B

W/Bl

Y/B

Y/G

Y/W

Orange with Yellow tracer

Red with Black tracer

White with Black tracer

White with Blue tracer

Yellow with Black tracer

Yellow with Green tracer

Yellow with White tracer

WVHDVICIEJNIHIM

ENGINE

KILL

FRONT

BRAKE STARTER

SPEEDOMETER

INDICATOR LIGHT

SWITCH SWITCH BUTTON

RU'iii'=

,OFFI

I

I

I

~

: 'ONI'fT"PUSHIf1'

H: HIGH BEAM INDICATOR LIGHT

N: NEUTRAL INDICATOR LIGHT

T: TURN SIGNAL INDICATOR LIGHT co

O.

mm

0,. #

"0'.' '0 j

I ttl

I cp I

I

(5

I

~'j'): ;:

CDI UNIT

IGNITION COIL ~

;;: §

, 1

III

I!III~ a'P

~~~Cfo

I

SIDE STAND

SWITCH

ON

OFF

GB/wl

(!) iii

REAR BRAKE

SWITCH

I u"IOf'

OFF o

I

TURN

~

SIGNAL

STAND

SIDE

~

.L.....J. i·e

99~~ Q:9

I! co o ~

U

.L9-th-B---/'Q

B/W-IJ..I"B/W~

TAILIBRAKE LIGHT

FRONT TURN SIGNAL LIGHT IRI rc:h-B-rfi-

Lg-

~B/WVB/W

HEADLIGHT

@B~

DB~w

1

;------l

@Js~wtDs:tv

FRONT TURN SIGNAL LIGHT ILl

I I I I I I I I

I-

W/Bi:I!-W/B

Br....(h..Br~

B/W-lJ..l"B/W~

LICENSE LIGHT

B~w:(lts~W®

REAR TURN SIGNAL LIGHT ILl

<!:t!t!!!::

II II

HORN BUTTON R

TURN SIGNAL

PASSING

LIGHT

LIGHT SWITCH BUTTON

M l1!!!!:

HORN u

DIMMER

SWITCH

1-';;=,+--+++-1 t~~t~~~212~~j

(!)

):

~

WIRE COLOR

B Black

BI : Blue h 111111111

tit

itH 11 1111

~

I."O;:;N?~~/!YjI)1ml ~i:ITit:g:; :~~, ~j R

Lg o

W

Y

BIBI

BILg

BIO

BIR

Br

G

Gr

Lbl

M NEUTRAL REGULATORI GENERATOR B/W

SWITCH RECTIFIER

~//

BIIB

BI/W:

G/BI

F: MAIN FUSE

M: STARTER MOTOR

O/W

OIY

RIB

W/B

W/BI:

Y/B

YIG

Y/W

Brown

Green

Gray

Light blue

Light green

Orange

Red

White

Yellow

Black with Blue tracer

Black with Light green tracer

Black with Orange tracer

Black with Red tracer

Black with White tracer

Blue with Black tracer

Blue with White tracer

Green with Blue tracer

Orange with White tracer

Orange with Yellow tracer

Red with Black tracer

White with Black tracer

White with Blue tracer

Yellow with Black tracer

Yellow with Green tracer

Yellow with White tracer

"T1

...

» en

...

Q)

Dr

":'" cc en m

:::ICI

:5 n

2

C)

2

"'1'\

CI

:::ICI s:

:1:0

::!

CI

2

FRONT

BRAKE STARTER

LIGHTING

SWITCH

ENGINE

KILL

SWITCH

SPEEDOMETER

H: HIGH BEAM INDICATOR LIGHT

N: NEUTRAL INDICATOR LIGHT

T: TURN SIGNAL INDICATOR LIGHT

~

INDICATOR LIGHT

~

~

"~U~Ni[:E~~~~~~~!:~~~j m ,JJ

~~

# ### I'

" 0' ., m l c e l .

'0-0' t

CDI UNIT ~

II

Illil

a~ ~~~l(o

;: § m i

FRONT TURN SIGNAL LIGHT IRI

1 rch-B--rf1Lg-

~BIWVBIW

HEADLIGHT

@B~

FRONT TURN

@t~~-(]tBJ

I I I I

B/W

~~w:r1)o7w

IGNAL LIGHT ILl

II I I I

II

rr===r

SIDE STAND

SWITCH ~

I

REAR BRAKE URN

STAND

"'." II

i·:

I--

~~~~

B/W-lJ.l-B AKE LIGHT

TAIL/BR

B/W-c3l-B/W

W/B-t::!:tW/B

Br-l'h-Br~

B/W-lJ.l-B/W~

LICENSE LIGHT

BrwjJt7,v@

REAR TURN SIGNAL LIGHT ILl ci:: 0

I I t ~ .:.

III r

HORN BUTTON

L

PUSH

R

Lg Lbl B

TURN SIGNAL

LIGHT SWITCH

QjXIlEiIfOI

PASSING DIMMER

SWITCH LIGHT

BUTTON

P

LOCK

OFF

I Rio b/YlB/WGrI Br

ON

IGNITION SWITCH

CLUTCH

LEVER

POSITION

SWITCH

llt

1111 ' " " " cO ;;: I

OJ

d

o~

'm"

lllll

HUffily

f~~~~F+=~~~ ~

NEUTRAL REGULATOR! GENERATOR

SWITCH RECTIFIER

FUSE BOX

CD:

HEADLIGHT IHII

(2): HEADLIGHT ILOI

~ ." ~

M)~

STARTER

RELAY

F: MAIN FUSE

M: STARTER MOTOR

;;:

--

Lbl

Lg o

R

W

Y

WIRE COLOR

B Black

81 Blue

Br

G

Gr

Brown

Green

Gray

Light blue

Light green

B/BI

B/Lg

BID

B/R

B/W

BIIB

BIIW·

GIBI

OIW

DIY

RIB

WIB

WIBI

YIB

YIG

Y!W

Orange

Red

White

Yellow

Black with Blue tracer

Black with Light green tracer

Black with Orange tracer

Black with Red tracer

Black with White tracer

Blue with Black tracer

Blue with White tracer

Green with Blue tracer

Orange with White tracer

Orange with Yellow tracer

Red with Black tracer

White with Black tracer

White with Blue tracer

Yellow with Black tracer

Yellow with Green tracer

Yellow with White tracer

Q)

::s c. en

:e

;::;"

N

CD

:::!.

Q)

::s c.

"T1

...

»

c::::

.....

:::!,

Q)

=

5

2

~

2

"T'I

-

C)

":"I

Q

=

.... is

2

SPEEDOMETER

ENGINE

KILL

FRONT

BRAKE STARTER

LIGHTING

SWITCH

SWITCH SWITCH BUTTON

~~~10f0 11~:I01Ollpu'sHI Ok) eFFIilifQ]

I

OSN.

INDICATOR LIGHT

H: HIGH BEAM INDICATOR LIGHT

N: NEUTRAL INDICATOR LIGHT

T: TURN SIGNAL INDICATOR LIGHT

It a~ ####

,b.-'

I~ rrw

~O-~~ ~ a"" , •

~ ~

I

FRONT TURN SIGNAL LIGHT IR}

~B-ff'l-.Lg­

~B/WVB/W

HEADLIGHT

~~

POSITION LIGHT

@]B~w(]ts~w

I

;::::=:::r

@lB~w.Osrw

FRONT TURN SIGNAL LIGHT IL}

B/BI B

PUSH

L

PUSH

Lg Lbl B

~'"'

•

PUSH

HORN BUTTON R

TURN SIGNAL

PASSING

LIGHT

LIGHT SWITCH BUTTON

SIDE STAND

SWITCH

OFF g

G I

.

REAR BRAKE

H TURN Su:~TC ~k~~~L

OFF 0 I SIDE

"'".

RESISTOR ffi1 ' ,

--J. illiiM

. ~ o ~

STAND

I I

~®e

W95

>fI

U~

.Lg-{'h-B~

B/W.y..B/W~

Gr--cl:l- Gr

B/W-c3l-B/w

W/B-c3l-w/B

TAILIBRAKE LIGHT @

I--

Br....fh-B~

B/W.y..B/W~

LICENSE LIGHT

B~w:GtsfW@

REAR TURN SIGNAL LIGHT ILl

,".0 I a.'

*t

I ~ I I I I I I I ~

» , " . ,

~

~

~

NEUTRAL

SWITCH

RECTIFIER

","",m~n::

FUSE BOX

CD: HEADLIGHT IHII

0: HEADLIGHT ILO}

'W,""

F: MAIN FUSE

M: STARTER MOTOR

WIRE COLOR

B Black

BI : Blue

GIBI

O/W

OIY

R/8

W/8

W/81

Y/8

Y/G

Y/W

Br

G

Gr

Lbl

Brown

Green

Gray

Light blue

Lg

0

R

W

Y

8/81

8/Lg

8/0

8/R

8/W

Light green

Orange

Red

White

Yellow

Black with Blue tracer

Black with Light green tracer

Black with Orange tracer

Black with Red tracer

Black with White tracer

81/B Blue with Black tracer

81/W: 81ue with White tracer

Green with Blue tracer

Orange with White tracer

Orange with Yellow tracer

Red with Black tracer

White with Black tracer

White with Blue tracer

Yellow with Black tracer

Yellow with Green tracer

Yellow with White tracer

"T1

0

....

:::r

(1)

1":-1 en m

::s n

....

:2

:::r C')

(1)

""

2 on

C)

=

:to

-I

0

2

WIRE, CABLE AND HOSE ROUTING

WIRE ROUTING

Clamp

Handlebar switch (R)

Clamp

Handlebar switch (L)

Clutch lever position switch

Speedometer

SERVICING INFORMATION 7-12

Lead wire cover-t--\t-~

I+---Front brake hose

Clamp

Blue tape

Clutch lever position switch

Throttle cable

Starter cable

Blue tape

Clamp

Wiring harness

Throttle position switch

(Except for E-03, 18,28 and 33)

Handlebar switch (L)

Clutch lever position switch

Clamp

Ignition switch

Wiring harness

Clamp

Wiring harness

Clamp

Wiring harness

Ignition switch

Clamp

Battery

8

Clamp

Wiring harness

Rear turn signal light (R)

License light

Fuse bOx--"""''''''O'''k~'''"/-Y\

Starter relay--+

","''''''''''''::77

Wiring harness

Starter motor

Clamp motor

Clamp

7-13 SERVICING INFORMATION

Clamp

Wiring harness

Clutch lever position switch

Throttle cable

Clamp

Wiring harness

Throttle position switch

(Except for E-03, 18,28 and 33)

Clamp

Wiring harness

Generator

Neutral switch

Rear brake switch

White tape

Neutral switch

Rear brake switch

Clamp

Wiring harness

Rear brake switch

Side stand switch

Generator

Clamp

Grenerator lead wire

Clamp

Tail/Brake light

Rear turn signal light

Wiring harness

Generator

Rear brake--__ switch coupler

Clamp

License light

Side stand switch

Clamp

Rear turn signal light (R)

License light

Side stand switch

Clamp

Clamp

(Right side)

Rear turn signal light (L)

Tail/Brake light

Clamp

(Left side)

Forward

....---

Starter motor Starter motor lead wire

--+--Crankcase (R)

--+I=-'\'\-Breather cover

"l::z:~_W-t~4--

Neutral switch

Ignition coil--++-+--1r

High-tension cord ------11M

(short cord)

High-tension cord

(long cord)

SERVICING INFORMATION 7·14

7·15 SERVICING INFORMATION

CABLE ROUTING

Clutch cable

Clutch cable

Throttle cables

Starter cable

Clutch cable holder

Th rottl e ca b I e-.,-'----,f----f:'~~

Fix the clutch cable with a clamp.

Clutch cable

Brake hose

Brake hosE~-+--H

Clutch cable

Clamp

Starter cable

Throttle cable

(pull)

Ignition switch lead wire

Cable guide

Speedometer----\ cable

Cable guide-----i

SERVICING INFORMATION 7·16

Clamp

Starter cable

""vacuum hose

. / Fuel hose

, Carburetor air hose

Carburetor clamp position

LH ?[S-RH

-<

Crankcase breather hose

VIEW A

LH

Upper $

RH

VIEW B

Carburetor air hose

Clutch cable

Air vent hose

• Pass through the air vent hose outside of the clutch cable.

• Pass through the breather hose inside of the clutch cable.

• Pass through the crankcase breather hose inside of the carburetor air hose.

(") r m

»

:2 m

:0

:::I:

0 tn m

-

:0

0

C

-f

:2

G)

(")

»

'";'I

.......

'""-I

:0 en to

C

:0

» m

:s

:0 n m z

-f C")

0 z

"" s:

:2

~

C

=

Ci z

»

:0

Rear brake switch

Carburetor overflow hose

Pass through the carburetor overflow hose between the engine and frame.

PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING

(For Austria and Switzerland)

SERVICING INFORMATION 7-18

Pass through the PAIR control valve vacuum hose and air supply hose between the engine mounting plates.

Air supply hose

PAl R control valve----\------+----If.k vacuum hose

PAIR control valve--~:s~~~

PAIR air pipe------+'.

When installing the brake hose, face the mark on the brake hose

<'::,.

Washer

~~.~

~

Throttle cable

Brake hose

Clutch cable kil

Starter cable

Brake hose

Master cylinder --,=C}lJ Hose guide

Brake hose

Clamp J

I ]

Washer

After touching the brake hose union tighten the union bolt to the specified torque.

-

J:J

0

C

-I

:2

G)

"T1

J:J

0

:2

-I aJ

J:J

»

"

....

= en m

::a

<

~

2

C)

2

"TI m C)

::a

:I:

0 m s::

:too

- f en C5

2 l,..Jll;rl Cia m p

SERVICING INFORMATION 7-20

REAR BRAKE HOSE ROUTING

Master cylinder

Brake hose---ffJ

Brake hose guide

4ci'H---Reservoir tank hose

VIEW A

After touching the brake hose union to the stopper, tighten the union bolt to the specified torque_

Ai~~J---Reservoir tank

Pass through the reservoir tank hose between the frame and brake hose union.

Brake hose guide

Bmk' hO"-!

VIEW B

7-21 SERVICING INFORMATION

HEAT SHIELD ADHERING

Right frame cover

SIDE STAND SPRING SET-UP

Side stand

Inner spring

Outer spring

SERVICING INFORMATION 7·22

SPECIAL TOOLS

09900-00401

"L" type hexagon wrench set

;:::::

~

{f[[qg

09900-00410

Hexagon bit wrench 09900-06107 set Snap ring pliers

09900-06108

Snap ring pliers

09900-09003

Impact driver set

09900-20102

Vernier calipers

09900-20202

Micrometer

(25-50 mm)

09900-20204

Micrometer

(75-100 mm)

09900-20205

Micrometer

(0-25 mm)

09900-20508

Cylinder bore gauge set

09900-20513

Gauge rod 94 mm

09900-20605

Dial calipers

09900-20606

Dial gauge (1/100)

09900-20701

Magnetic stand

09900-20803

Thickness gauge

09900-21304

V-block (100 mm)

09900-22301

Plastigauge

09900-25002

Pocket tester

09900-28106

Electro tester

09910-20116

Conrod holder

09910-32830

Crankshaft installer attachment

09910-32860

Crankshaft installer attachment

~

09910-60611

Universal clamp 09910-33210

Attachment wrench

09910-32812

Crankshaft installer

09913-10720

Compression gauge attachment

09913-50121

Oil seal remover

09913-60910

Bearing/gear puller

09913-75810

Bearing installer

09913-75830

Bearing installer

09915-64510

Compression gauge

7·23 SERVICING INFORMATION

09915-74510

Oil pressure gauge

09916-14510

Valve spring compressor

09916·14910

Valve spring compressor attachment

09916·20610

Valve seat cutter head 15° (N-121J

09916-24210

Valve seat cutter head 45° (N-615J

09916-24900 09916·34550

5.5 mm reamer

09916-34580

10.8 mm reamer

09916-44910 09916-84511

Valve guide remover Tweezers

09917·23711

Ring nut socket wrench

09920-13120 09920-53740

Crankcase separator! Clutch sleeve hub crankshaft remover holder

09923· 73210

Bearing remover

09923·74510

Bearing remover

09924-84510

Bearing installer set

09924·84521

09925-18010

Steering bearing

Bearing installer set installer

,

09930-30102

Sliding shaft

09930·33720

Generator rotor remover

09930-73110

Starter torque limiter holder

09930· 73120

Starter torque limiter socket

09940·14911

Steering nut socket wrench

~:t

09941-34513

09940·52860

Front fork oil seal installer

Steering race and swingarm bearing installer

09940·14960

Steering nut wrench socket

09940-34520

"T" handle

09940-34592

Attachment G

09930·11920

Torx bit JT40H

09930·11940

T orx bit holder

09941-50111

Wheel bearing remover

09941-54911

Bearing outer race remover

09941-74910

Steering bearing remover

09943-74111

Front fork oil level gauge

SERVICING INFORMATION 7-24

7·25 SERVICING INFORMATION

TIGHTENING TORQUE

ENGINE

ITEM

Cylinder head cover bolt

Camshaft sprocket bolt

Cylinder head bolt

Cylinder head nut

Cylinder base nut

Cam drive chain tensioner fitting bolt

Generator rotor bolt

Can drive chain adjuster mounting bolt

Spark plug

Crankcase bolt

T.D.C. plug

Oil gallery

Oil nozzle bolt

Generator cover plug

Starter clutch bolt

Primary drive gear nut

Clutch spring mounting bolt

Clutch sleeve hub nut

Gearshift arm stopper

Engine oil drain plug

Engine sprocket bolt

Engine mounting bolt 8 mm Diam.

Engine mounting bolt 10 mm Diam.

Engine mounting bracket bolt (Upper and

Front)

(Rear)

Exhaust pipe bolt

Muffler mounting bolt

Crankshaft bearing ring nut

Engine oil pipe union bolt (Cylinder head)

Engine oil cooler hose bolt

(Crankcase)

Cam drive chain adjuster cap bolt

40

23

26

26

80

23

20

10

6

11

23

23

10

15

25

100

10

50

19

23

N·m

10

15

38

25

10

13

160

10

11

6

40

65

29.0

16.5

19.0

19.0

58.0

16.5

14.5

7.0

4.5

11.0

18.0

72.5

7.0

36.0

13.5

16.5

4.5

29.0

47.0

Ib-ft

7.0

11.0

27.5

18.0

7.0

9.5

115.5

7.0

8.0

8.0

16.5

16.5

7.0

4.0

2.3

2.6

2.6

8.0

2.3

2.0

1.0

0.6

1.5

2.5

10.0

1.0

5.0

1.9

2.3

0.6

4.0

6.5 kg-m

1.0

1.5

3.8

2.5

1.0

1.3

16.0

1.0

1.1

1 .1

2.3

2.3

1.0

CHASSIS

ITEM

Front axle

Front axle holder nut

Front fork damper rod bolt

Front fork lower clamp bolt

Front fork upper clamp bolt

Front fork cap bolt

Steering stem head nut

Handlebar clamp bolt

Handlebar holder nut

Front brake master cylinder mounting bolt

Front brake caliper mounting bolt

Brake caliper axle bolt (Front & Rear)

Brake hose union bolt (Front & Rear)

Brake pad mounting pin (Front & Rear)

Front brake pad mounting pin plug

Brake air bleeder valve (Front & Rear)

Brake disc mounting bolt (Front & Rear)

Swingarm pivot nut

Front footrest bolt

Chain roller mounting bolt (Upper & Lower)

Rear brake master cylinder mounting bolt

Rear brake rod lock nut

Rear shock absorber bolt (Upper & Lower)

Rear cushion lever nut (Front)

Rear cushion lever nut (Center)

Rear cushion rod nut

Rear axle nut For Canada and U.S.A.

For the others

Rear sprocket mounting nut

Spoke nipple (Front & Rear)

N·m

65

10

26

23

13

23

18

90

23

25

10

2.5

8

23

77

39

40

10

18

30

26

29

23

55

80

100

100

100

110

27

4.5

SERVICING INFORMATION 7·26 kg-m

5.5

8.0

10.0

10.0

10.0

11.0

2.7

0.45

2.3

1.8

0.25

0.8

2.3

7.7

3.9

4.0

1.0

1.8

6.5

1.0

3.0

2.6

2.9

2.3

9.0

2.3

2.5

1.0

2.6

2.3

1.3

Ib-ft

40.0

58.0

72.5

72.5

72.5

79.5

19.5

3.0

16.5

13.0

1.8

6.0

16.5

55.5

28.0

29.0

7.0

13.0

47.0

7.0

21.5

19.0

21.0

16.5

65.0

16.5

18.0

7.0

19.0

16.5

9.5

7-27 SERVICING INFORMATION

TIGHTENING TORQUE CHART

For other bolts and nuts listed previously, refer to this chart:

Bolt Diameter

@(mm)

10

12

14

16

18

4

5

6

8 13

29

45

65

105

160

Conventional or "4" marked bolt

N·m kg-m Ib-ft

1.5

3

5.5

0.15

0.3

0.55

1.0

2.0

4.0

1.3

2.9

4.5

6.5

10.5

16.0

9.5

21.0

32.5

47.0

76.0

115.5

N·m

2.3

4.5

10

23

50

85

135

210

240

"7" marked bolt kg-m

0.23

0.45

1.0

2.3

5.0

8.5

13.5

21.0

24.0

Ib-ft

1.5

3.0

7.0

16.5

36.0

61.5

97.5

152.0

173.5

Conventional bolt "4" marked bolt "7" marked bolt

SERVICING INFORMATION 7·28

SERVICE DATA

VALVE

+

GUIDE

Valve diam.

ITEM

Valve clearance

(when engine is cold)

Valve guide to valve stem clearance

Valve stem deflection

Valve guide 1.0.

Valve stem 0.0.

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.)

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

33

(1.3)

28

( 1 . 1 )

0.08-0.13

(0.003-0.005)

0.17-0.22

(0.0067 -0.0087)

0.010-0.037

(0.0004-0.0015)

0.030-0.057

(0.0012-0.0022)

- -

5.500-5.512

(0.2165-0.2170)

5.475-5.490

(0.2156-0.2161)

5.455-5.470

(0.2148-0.2154)

- -

- -

- -

0.9-1.1

(0.035-0.043)

- -

- -

- -

5.9-6.7 kg

(13.0-14.8Ibs) at length 27.5 mm (1.1 in)

13.8-15.8 kg

(30.4-34.8 Ibs) at length 31.0 mm (1.2 in)

Unit: mm (in)

LIMIT

- -

- -

- -

- -

- -

- -

0.35

(0.014)

- -

- -

- -

0.05

(0.002)

0.5

(0.02)

2.7

(0.11)

- -

0.03

(0.001 )

34.4

(1.35)

38.1

(1.50)

- -

- -

7-29 SERVICING INFORMATION

CAMSHAFT

+

CYLINDER HEAD

Cam height

ITEM

IN.

EX.

Camshaft journal oil clearance Right &

Center

Camshaft journal holder 1.0.

Left

Right &

Center

Camshaft journal 0.0.

Left

Right &

Center

Left

Camshaft runout

Rocker arm 1.0.

Rocker arm shaft 0.0.

Cylinder head distortion

Cylinder head cover distortion

IN. & EX.

IN. & EX.

STANDARD

33.710-33.750

(1.3272-1.3287)

33.700-33.740

( 1.3268-1.3283)

0.032-0.066

(0.0013-0.0026)

0.028-0.059

(0.0011-0.0023)

22.012-22.025

(0.8666-0.8671 )

17.512-17.525

(0.6894-0.6900)

21.959-21.980

(0.8645-0.8654)

17.466-17.484

(0.6877 -0.6883)

- -

12.000-12.018

(0.4724-0.4 731)

11.973-11.984

(0.4714-0.4718)

- -

- -

CYLINDER

+

PISTON

+

PISTON RING

ITEM

Piston to cylinder clearance

Cylinder bore

Piston diam.

STANDARD

0.020-0.030

(0.0008-0.0012)

100.000-100.015

(3.937 -3.9376)

99.975-99.990

(3.9360-3.9366)

Measure at 21 mm (0.8 in) from the skirt end.

Cylinder distortion

- -

Piston ring free end gap

Piston ring end gap

Compression pressure

(Automatic decomp. actuated)

1 st R

2nd R

1 st

2nd

Approx.

Approx.

13.5

(0.53)

11.4

(0.45)

0.30-0.45

(0.012-0.018)

0.45-0.60

(0.018-0.024)

850 kPa

Approx. (8.5 kg/cm

2 )

120 psi

Unit: mm (in)

LIMIT

0.120

(0.0047)

Nicks or

Scratches

99.880

(3.9323)

0.05

(0.002)

10.8

(0.43)

9.1

(0.36)

0.50

(0.020)

1.00

(0.039)

- -

Unit: mm (in)

LIMIT

33.410

(1.3154)

33.400

(1.3150)

0.150

(0.0059)

0.150

(0.0059)

- -

- -

- -

- -

0.10

(0.004)

- -

- -

0.05

(0.002)

0.05

(0.002)

ITEM

Piston ring to groove clearance

Piston ring groove width

Piston ring thickness

1 st

2nd

1 st

2nd

Oil

1 st

2nd

Piston pin bore

Piston pin 0.0.

STANDARD

- -

- -

1.230-1.250

(0.048-0.049)

1.210-1.230

(0.047-0.048)

2.810-2.830

(0.110-0.111)

1.170-1.190

(0.0461 -0.0469)

1.150-1.170

(0.0453-0.0461 )

23.002- 23.008

(0.9056-0.9058)

22.996-23.000

(0.9054-0.9055)

CONRaD

+

CRANKSHAFT

ITEM

Conrod small end 1.0.

Conrod deflection

Conrod big end side clearance

Conrod big end width

Crankshaft runout

Crank web to web width

STANDARD

23.006-23.014

(0.9057-0.9061 )

- -

0.10-0.65

(0.004-0.026)

24.95-25.00

(0.982-0.984)

- -

71.0±0.1

(2.795 ± 0.004)

OIL PUMP

ITEM

Oil pump reduction ratio

Oil pressure (at 60oC,1400F)

STANDARD

1.633 (61/28 x 30/20 x 15/30)

Above 30 kPa (0.3 kg/cm2, 4.3 psi)

Below 70 kPa (0.7 kg/cm2, 10.0 psi) at 3 000 r/min.

SERVICING INFORMATION 7·30

LIMIT

0.180

(0.0071 )

0.150

(0.0059)

- -

- -

- -

- -

- -

23.030

(0.9067)

22.980

(0.9047)

Unit: mm (in)

LIMIT

23.040

(0.9071 )

3.0

(0.12)

1.00

(0.039)

- -

0.05

(0.002)

- -

LIMIT

- -

- -

7·31 SERVICING INFORMATION

CLUTCH

ITEM

Clutch lever play

Drive plate thickness

Driven plate distortion

Clutch spring free length

No.1 &

No.2 I

STANDARD

10-15

(0.4-0.6)

2.9-3.1

(0.11 -0.12)

- -

- -

Unit: mm (in)

LIMIT

- -

2.6

(0.10)

0.10

(0.004)

33.0

(1.30)

TRANSMISSION

+

DRIVE CHAIN

ITEM

Primary reduction ratio

Final reduction ratio

E-03,28,33

The others

Gear ratios Low

2nd

3rd

4th

Top

Shift fork to groove clearance

Shift fork groo\le width

Shift fork thickness

Drive chain

Drive chain slack

Type

Links

STANDARD

2.178 (61/28)

2.800 (42115)

2.733 (41/15)

2.416 (29112)

1.625 (26116)

1.238 (26/21)

1.000 (21/21)

0.826 (19123)

0.10-0.30

(0.004-0.012)

5.0-5.1

(0.197 -0.200)

4.8-4.9

(0.189-0.193)

DAIDO:DID525V9

20-pitch length

110

I

30-45

(1.2-1.8)

Unit: mm (in) Except ratio

LIMIT

- -

- -

- -

- -

- -

- -

- -

- -

- -

0.50

(0.020)

- -

- -

- -

- -

319.4

(12.57)

- -

SERVICING INFORMATION 7-32

CARBURETOR

ITEM

Carburetor type

Bore size

1.0. No.

Idle r/min.

Float height

Main jet

Jet needle

Needle jet

Throttle valve

Pilot jet

Starter jet

Pilot screw

Throttle cable play

(pulling cable)

Starter cable play

(M.J.)

(J.N.)

(N.J.)

(Th.V.)

(P.J.)

(G.S.)

(P.S.)

E-03

MIKUNI

BST40SS

40 mm

32E1

1 500± 100 r/min.

14.7± 1.0 mm

(0.58 ± 0.04 in)

#JLIO

6F23

Y-5M

#95

#Lf25

#40

PRE-SET

0.5-1.0 mm

(0.02-0.04 in)

0.5-1.0 mm

(0.02-0.04 in)

CARBURETOR

ITEM

Carburetor type

Bore size

1.0. No.

Idle r/min.

Float height

Main jet

Jet needle

Needle jet

Throttle valve

Pilot jet

Starter jet

Pilot screw

Throttle cable play

(pulling cable)

Starter cable play

(M.J.)

(J.N.)

(N.J.)

(Th.V.)

(P.J.)

(G.S.)

(P.S.)

E-02,04,34

MIKUNI

BST40SS

40 mm

32EO

1 500±

100 r/min.

14.7± 1.0 mm

(0.58 ± 0.04 in)

# 140

6F19-3rd

Y-5

#95

#42.5

#40

PRE-SET

(1 1 /2 turns back)

0.5-1.0 mm

(0.02-0.04 in)

0.5-1.0 mm

(0.02-0.04 in)

+-

+-

+-

+-

+-

+-

+-

+-

SPECIFICATION

E-33 E-28

++-

+-

32E6

+-

+-

32E5

+-

+-

# 140

6F19-3rd

Y-5

+-

#42.5

+-

PRE-SET

(1112 turns back)

++-

++-

E-18

- -

+-

+-

32E2

1 500± 50 r/min.

+-

# 137.5

6H21-4th

+-

+-

+-

+-

PRE-SET

(1.0 turn back)

+-

+-

+-

+-

+-

+-

+-

+-

+-

+-

SPECIFICATION

E-37 E-17,22,24 U-type E-22

+++-

+-

32E8

+-

+-

32E3

+-

+-

32E4

+-

+-

++-

+-

+-

+-

+-

+-

+-

+-

+-

+-

+-

++-

PRE-SET PRE-SET

(1.0 turn back) (11/8 turns back)

++-

+++-

7·33 SERVICING INFORMATION

ELECTRICAL

ITEM

Ignition timing

Spark plug

Spark performance

Ignition coil resistance

SPECIFICATION

10° B.T.D.C. at 1 500 r/min.

Type

Gap

NO.: U31 ESR-N

N.G.K.: CR10E

0.7-0.8

(0.028-0.031 )

Primary

Over 8 (0.3) at 1 atm.

0.07-0.12 Q

Secondary 23-25 kQ

Generator coil resistance

Generator no-load voltage

Generator Max. output

Regulated voltage

Starter relay resistance

Battery Type designation

Capacity

Standard electrolyte S.G.

Fuse size Main

Headlight (H)

Headlight (L)

Charging

Power source

0.5-0.9 Q

0.1-0.2 Q

Pick-up 170-256 Q

More than 75 V(AC) at 5 000 r/min.

Approx. 200W at 5 000 r/min.

13.0-16.0 V at 5 000 r/min.

3-5Q

YTX9-BS

12V 28.8 kC (8Ah)!1 0 HR

1.320 at 20°C (68°F)

30 A

10 A

10 A

WATTAGE

ITEM

Headlight I HI

I

LO

Parking or position light

Tail/Brake light

Turn signal light

Speedometer light

Turn signal indicator light

High beam indicator light

Neutral indicator light

License light

BRAKE

+

WHEEL

ITEM

Rear brake pedal height

Brake disc thickness

Brake disc runout

Front

Rear

Unit: mm (in)

NOTE

B-B/W

Plug cap-

Plug cap y-y

B-W

BI-G

SPECIFICATION

E-03,24,28,33

60

55

5/21

21

3

2

2

2

5

The others

-

-

-

4

-

-

-

-

-

Unit: mm (in)

STANDARD

5

(0.2)

4.0

(0.157

± 0.2

± 0.008)

4.5

(0.177

± 0.2

± 0.008)

- -

Unit:W

LIMIT

- -

3.5

(0.14)

4.0

(0.16)

0.30

( 0.012 )

ITEM

Master cylinder bore

Master cylinder piston diam.

Brake caliper cylinder bore

Brake caliper piston diam.

Wheel rim runout

Wheel axle runout

Tire rim size

Tire size

Tire tread depth

SUSPENSION

ITEM

Front fork stroke

Front fork spring free length

Front fork oil level

Front

Rear

Axial

Radial

Front

Rear

Front

Rear

Front

Rear

Front

Rear

Front

Rear

Front

Rear

Front

Rear

STANDARD

260

(10.2)

220

(8.7)

~-

164

(6.5)

150

(5.9)

STANDARD

12.700-12.743

(0.5000-0.5017)

12.700-12.743

(0.5000-0.5017)

12.657 -12.684

(0.4983-0.4994)

12.657 -12.684

(0.4983-0.4994)

27.000-27.050

( 1.0630-1.0650)

30.23-30.28

(1.1902-1.1921)

26.90-26.95

(1.0591-1.0610)

30.16-30.18

(1.1874-1.1882)

- -

- -

- -

- -

21x1.85

17 x MT2.50

90/90-21 545

1 20/90-1 7 645

- -

- -

SERVICING INFORMATION 7-34

LIMIT

- -

- -

~-

- -

- -

- -

~-

~-

2.0

(0.08)

2.0

(0.08)

0.25

(0.010)

0.25

(0.010)

- -

- -

- -

~-

3.0

(0.12)

3.0

(0.12)

Unit: mm (in)

NOTE LIMIT

- -

- -

548

(21.6)

- -

~-

Low seat

Low seat

7·35 SERVICING INFORMATION

ITEM

Rear shock absorber spring pre-set length

Rear wheel travel

Swingarm pivot shaft runout

STANDARD

247.5

(9.74)

260

(10.2)

220

(8.7)

- -

LIMIT

- -

- -

- -

0.3

(0.01 )

NOTE

Low seat

TIRE PRESSURE

COLD INFLATION

TIRE PRESSURE

FRONT

REAR

SOLO RIDING kPa kg/cm2 psi

DUAL RIDING kPa kg/cm2 psi

150 1.50 22 175 1.75 25

175 1.75 25 200 2.00 29

FUEL+OIL

Fuel type

ITEM

Fuel tank including reserve reserve

SPECIFICATION

Use only unleaded gasoline of at least 87 pump octane (R; M) or 91 octane or higher rated by the research method.

Gasoline containing MTBE (Methyl Tertiary

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

NOTE

E-03,33

Use only unleaded gasoline of at least 87 pump octane ( R; M method) or 91 octane or higher rated by the Research Method.

E-28

Gasoline used should be graded 85-95 octane or higher. An unleaded gasoline is The others recommended.

12 L

(3.2/2.6 US/Imp gal)

E-33

13 L

(3.4/2.9 US/Imp gal)

3.0 L

(0.8/0.7 US/Imp gal)

The others

Engine oil type

Engine oil capacity

Front fork oil type

Front fork oil capacity (each leg)

SAE 10W/40, API SE, SF or SG

Change

2 300 ml

(2.4/2.0 US/Imp qt)

Filter change

Overhaul

2 400 ml

(2.5/2.1 US/Imp qt)

2 600 ml

(2.7/2.3 US/Imp qt)

Fork oil # 10

Brake fluid type

565 ml

(19.1119.9 US/Imp oz)

563 ml

(19.0/19.8 US/Imp oz)

DOT 4

Low seat

8-1 EMISSION CONTROL INFORMATION

EMISSION CONTROL CARBURETOR COMPONENTS

DR650SE motorcycles are equipped with precision, manufactured carburetors for emission level control. These carburetors require special mixture control components and other precision adjustments to function properly.

There are several carburetor mixture control components in each carburetor assembly. Three (3) of these components are machined to much closer tolerances than standard machined carburetor jets.

These three (3) particular jets-MAIN JET, NEEDLE JET, PILOT JET -must not be replaced by standard jets. To aid in identifying these three (3) jets a different design of letter and number are used.

If replacement of these close tolerance jets becomes necessary, be sure to replace them with the same type close tolerance jets marked as in the examples shown below.

The jet needle is also of special manufacture. Only one clip position is provided on the jet needle.

If replacement becomes necessary the jet needle may only be replaced with an equivalent performing replacement component. Suzuki recommends that Genuine Suzuki Parts be utilized whenever possible for the best possible performance and durability.

Conventional Figures Used on Standard Tolerance Jet

Components

Emission Type Figures

Used on Close Tolerance

Jet Components

1

I

2 3 4 5 6 7 8 9 0

2 :1 Lf 5 5 '7 B g 0

The carburetor specifications for the emission-controlled DR650SE are as follows.

Carburetor

I.D. No.

32E6

(California model only)

Main

Jet

Needle

Jet

Jet

Needle

Pilot

Jet

#/40

Y-SM 6F23 #42.5

Pilot

Screw

PRE-SET

32E1

Adjusting, interferring with, improper replacement, or resetting of any of the carburetor components may adversely affect carburetor performance and cause the motorcycle to exceed the exhaust emission level limits. If unable to effect repairs, contact the distributors representative for further technical information and assistance.

EMISSION CONTROL INFORMATION 8-2

EVAPORATIVE EMISSION CONTROL SYSTEM

(California model only)

Fuel tank

Fuel filler pipe

Purge port

Carburetor

II!(

He VAPOR

• FUEL

4;.---

FRESH AIR

1 1 + - Canister

Surge hose

(Red stripe)

Fuel tank

Clamp

Purge air hose

Q)

=2

000

""'I-t

2.

m

Q)JJ

3J:

00 c..oo

~m

OJJ

2.0

<c

- - t -

:2

G)

2

"TI

CI

= s:

::z::,.

-4 is

2

CCI

W m s: en en

CI

2 n

C)

2

-4 =

IfJ----Purge air hose

DR650SEV/W/X/Y (’97/’98/’99/’00-MODELS)

CONTENTS

SPECIFICATIONS ................................................................................ 9- 1

SERVICE DATA .................................................................................... 9- 3

WIRING DIAGRAM ............................................................................... 9- 11

9

9·1

SPECIFICATIONS

DIMENSIONS AND DRY MASS

Overall length ............................. 2345 mm (92.3 in) ..... E-17, 18, 22

2325 mm (91.5 in) ..... E-17, 18, 22 (Low seat)

2255 mm (88.8 in) ..... Others

2235 mm (88.0 in) ..... Others (Low seat)

Overall width .............................. 865 mm (34.1 in)

Overall height ............................. 1 205 mm (47.4 in)

1 165 mm (45.9 in) ..... (Low seat)

Wheelbase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 490 mm (58.7 in)

1 475 mm (58.1 in) ..... (Low seat)

Ground clearance. . . . . . . . . . . . . . . . . . . . . . . . . . 265 mm (10.4 in)

225 mm ( 8.9 in) ..... (Low seat)

Seat height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 885 mm (34.8 in)

845 mm (33 in) ..... (Low seat)

Dry mass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 kg (324 Ibs)

ENGINE

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

Valve clearance (IN) ........................ 0.08-0.13 mm (0.003-0.005 in)

(EX) ....................... 0.17-0.22 mm (0.007-0.009 in)

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

Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 100 mm (3.937 in)

Stroke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 mm (3.228 in)

Piston displacement. . . . . . . . . . . . . . . . . . . . . . .. 644 cm 3 (39.3 cu. in)

Compression ratio ......................... 9.5: 1

Carburetor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. BST40, single

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

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

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

TRANSMISSION

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

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

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

Primary reduction ratio..................... 2.178 (61/28)

Gear ratios, Low........................... 2.416 (29/12)

2nd ........................... 1.625 (26/16)

3rd . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.238 (26/21)

4th. . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.000 (21/21)

Top ........................... 0.826 (19/23)

Final reduction ratio ........................ 2.800 (42/15) ..... E-03, 28, 33

2.733 (41/15) ..... Others

Drive chain ................................ 010525 V9, 110 links

CHASSIS

Front suspension

Rear suspension .......................... .

Front fork stroke .......................... .

Telescopic, coil spring, oil damped

Link type, coil spring, gas/oil damped, spring pre-load fully adjustable, compression damping force adjustable

260 mm (10.2 in)

220 mm ( 8.7 in) ..... (Low seat)

Rear wheel travel .......................... 260 mm (10.2 in)

220 mm ( 8.7 in) ..... (Low seat)

Steering angle ............................. 43°

Caster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 28° 30'

Trail ....................................... 111 mm (4.37 in)

Turning radius ............................. 2.5 m (8.2 tt)

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

Rear brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Disc brake

Front tire size. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 90/90-21 54S, tube type

Rear tire size .............................. 120/90-17 64S, tube type

ELECTRICAL

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

Ignition timing ............................. 10° B.T.D.C. at 1 500 rpm

Spark plug ................................. NGK CR10E or DENSO U31ESR-N

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

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

Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 30/10/10A

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

Parking or city light. . . . . . . . . . . . . . . . . . . . . . .. 12V 4W ..... except E-03, 24, 28, 33

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

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

License plate light ......................... 12V 5W

Speedometer light ......................... 12V 3W

Neutral indicator light. . . . . . . . . . . . . . . . . . . . .. 12V 2W

High beam indicator light .................. 12V 2W

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

CAPACITIES

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

Engine oil, oil change ..................... . with filter change .............. . overhaul ...................... .

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

12.0 L (3.2/2.6 US/Imp gal) ..... E-33

13.0 L (3.4/2.9 US/Imp gal) ..... Others

3.0 L (0.8/0.7 US/Imp gal)

2300 ml (2.4/2.0 US/Imp qt)

2400 ml (2.5/2.1 US/Imp qt)

2600 ml (2.7/2.3 US/Imp qt)

565 ml (19.1/19.9'US/lmp oz)

563 ml (19.0/19.8 US/Imp oz) ..... (Low seat)

9·2

9-3

SERVICE DATA

VALVE

+

GUIDE

ITEM

Valve diam.

IN.

EX.

Valve clearance

(when engine is cold)

IN.

EX.

Valve guide to valve stem clearance

Valve stem deflection

Valve guide 1.0.

Valve stem 0.0.

IN.

EX.

IN. & EX.

IN. & EX.

IN.

Valve stem runout

EX.

IN. & EX.

Valve head thickness

IN. & EX.

Valve stem end length

Valve seat width

IN. & EX.

IN. & EX.

Valve head radial runout

IN. & EX.

Valve spring free length

(IN. & EX.)

INNER

OUTER

Valve spring tension (IN. & EX.)

INNER

OUTER

STANDARD

33

(1.3)

28

(1.1)

0.08-0.13

(0.003-0.005)

0.17-0.22

(0.0067 -0.0087)

0.010-0.037

(0.0004-0.0015)

0.030-0.057

(0.0012-0.0022)

- -

5.500-_5.512

(0.2165-0.2170)

5.475-5.490

(0.2156-0.2161 )

5.455-5.470

(0.2148-0.2154)

- -

- -

- -

0.9-1.1

(0.035-0.043)

- -

- -

- -

5.9-6.7 kg

(13.0-14.8Ibs) at length 27.5 mm (1.1 in)

13.8-15.8 kg

(30.4-34.8 Ibs) at length 31.0 mm (1.2 in)

Unit: mm (in)

LIMIT

- -

- -

- -

- -

- -

- -

0.35

(0.014)

- -

- -

- -

0.05

(0.002)

0.5

(0.02)

2.7

(0.11 )

- -

0.03

(0.001)

34.4

(1.35)

38.1

(1.50)

- -

- -

CAMSHAFT

+

CYLINDER HEAD

ITEM

Cam height

IN.

EX.

Camshaft journal oil clearance Right &

Center

Camshaft journal holder

Camshaft journal 0.0.

1.0.

Left

Right &

Center

Left

Right &

Center

Left

Camshaft runout

Rocker arm 1.0.

IN. & EX.

Rocker arm shaft 0.0.

Cylinder head distortion

IN. & EX.

Cylinder head cover distortion

STANDARD

33.710-33.750

( 1.3272-1.3287)

33.700-33.740

(1.3268-1.3283)

0.032-0.066

(0.0013-0.0026)

0.028-0.059

(0.0011-0.0023)

22.012-22.025

(0.8666-0.8671 )

17.512-17.525

(0.6894-0.6900)

21.959-21.980

(0.8645-0.8654)

17.466-17.484

(0.6877 -0.6883)

- -

12.000-12.018

(0.4724-0.4731 )

11.973-11.984

(0.4714-0.4718)

- -

- -

CYLINDER

+

PISTON

+

PISTON RING

ITEM

Piston to cylinder clearance

Cylinder bore

Piston diam.

STANDARD

0.020-0.030

(0.0008-0.0012)

100.000-100.015

(3.937 -3.9376)

99.975-99.990

(3.9360-3.9366)

Measure at 21 mm (0.8 in) from the skirt end.

Cylinder distortion

- -

Piston ring free end gap

Piston ring end gap

Compression pressure

(Automatic decomp. actuated)

1 st R

2nd R

1 st

2nd

Approx.

Approx.

13.5

(0.53)

11.4

(0.45)

0.30-0.45

(0.012-0.018)

0.45-0.60

(0.018-0.024)

Approx. 850 kPa

(8.5 kg/cm 2 )

120 psi

Unit: mm (in)

LIMIT

0.120

(0.0047)

Nicks or

Scratches

99.880

(3.9323)

0.05

(0.002)

10.8

(0.43)

9.1

(0.36)

0.50

(0.020)

1.00

(0.039)

- -

Unit: mm (in)

LIMIT

33.410

(1.3154)

33.400

(1.3150)

0.150

(0.0059)

0.150

(0.0059)

- -

- -

- -

- -

0.10

(0.004)

- -

- -

0.05

(0.002)

0.05

(0.002)

9·4

9·5

ITEM

Piston ring to groove clearance

Piston ring groove width

Piston ring thickness

1 st

2nd

1 st

2nd

Oil

1 st

2nd

Piston pin bore

Piston pin O.D.

STANDARD

-.~

- -

1.230-1.250

(0.048-0.049)

1.210-1.230

(0.047-0.048)

2.810-2.830

(0.110-0.111)

1.170-1.190

(0.0461 -0.0469)

1.150-1.170

(0.0453 -0.0461)

23.002-23.008

(0.9056-0.9058)

22.996-23.000

(0.9054-0.9055)

CONROD + CRANKSHAFT

ITEM

Conrod small end I. D.

Conrod deflection

Conrod big end side clearance

Conrod big end width

Crankshaft runout

Crank web to web width

STANDARD

23.006- 23.014

(0.9057-0.9061)

0.10-0.65

(0.004-0.026)

24.95-25.00

(0.982-0.984)

----

71.0±0.1

(2.795 ± 0.004)

OIL PUMP

ITEM

Oil pump reduction ratio

Oil pressure (at 60°C,140°F)

STANDARD

1.633 (61/28 x 30/20 x 15/30)

Above 30 kPa (0.3 kg/cm2, 4.3 psi)

Below 70 kPa (0.7 kg/cm2, 10.0 psi) at 3 000 r/min.

LIMIT

0.180

(0.0071 )

0.150

(0.0059)

- -

_ . -

- - - - - - - -

- - -

23.030

(0.9067)

22.980

(0.9047)

Unit: mm (in)

LIMIT

23.040

(0.9071 )

3.0

(0.12)

1.00

(0.039)

- - - - - -

0.05

(0.002)

LIMIT

CLUTCH

ITEM

Clutch lever play

Drive plate thickness

Driven plate distortion

Clutch spring free length

No.1 &

No.2

I

STANDARD

10-15

(0.4-0.6)

2.9-3.1

(0.11 -0.12)

- -

- -

Unit: mm (in)

LIMIT

- -

2.6

(0.10)

0.10

(0.004)

33.0

( 1.30)

TRANSMISSION

+

DRIVE CHAIN

ITEM

Primary reduction ratio

Final reduction ratio

Gear ratios

E-03,28,33

The others

Low

2nd

3rd

4th

Top

Shift fork to groove clearance

Shift fork groove width

Shift fork thickness

Drive chain

Drive chain slack

Type

Links

Unit: mm (in) Except ratio

STANDARD

2.178 (61/28)

2.800 (42/15)

2.733 (41115)

2.416 (29/12)

1.625 (26116)

1.238 (26121)

1.000 (21/21)

0.826 (19/23)

0.10-0.30

(0.004-0.012)

5.0-5.1

(0.197 -0.200)

4.8-4.9

(0.189-0.193)

DAIDO:DID525V9

110

20-pitch length

I

30-45

(1.2-1.8)

- -

LIMIT

- -

- -

- -

- -

- -

- -

- -

- -

0.50

(0.020)

- -

- -

- -

- -

319.4

(12.57)

- -

9·6

9·7

CARBURETOR

ITEM

Carburetor type

Bore size

I.D. No.

Idle r/min.

Float height

Main jet

Jet needle

Needle jet

Throttle valve

Pilot jet

Starter jet

Pilot screw

Throttle cable play

(pulling cable)

Starter cable play

(M.J.)

(J.N.)

(N.J.)

(Th.V.)

(P.J.)

(G.S.)

(P.S.)

E-03

MIKUNI

BST40SS

40 mm

32E1

1 500± 100 r/min.

14.7± 1.0 mm

(0.58 ± 0.04 in)

#JLIO

6F23

Y-5M

#95

# Lj2.5

#40

PRE-SET

0.5-1.0 mm

(0.02-0.04 in)

0.5-1.0 mm

(0.02-0.04 in)

CARBURETOR

ITEM

Carburetor type

Bore size

I.D. No.

Idle r/min.

Float height

Main jet

Jet needle

Needle jet

Throttle valve

Pilot jet

Starter jet

Pilot screw

Throttle cable play

(pulling cable)

Starter cable play

(M.J.)

(J.N.)

(N.J.)

(Th.V.)

(P.J.)

(G.S.)

(P.S.)

E-02,04,34

MIKUNI

BST40SS

40 mm

32EO

1 500±

100 r/min.

14.7± 1.0 mm

(0.58±0.04 in)

# 140

6F19-3rd

Y-5

#95

#42.5

#40

PRE-SET

(11/2 turns back)

0.5-1.0 mm

(0.02-0.04 in)

0.5-1.0 mm

(0.02-0.04 in)

+-

+-

+-

+-

+-

+-

+-

+-

SPECIFICATION

E-33 E-28

++-

+-

32E6

+-

+-

32E1

+-

+-

+-

+-

+-

+-

+-

+-

+-

+-

+-

+-

+-

+-

+-

+-

+-

+-

+-

+-

+-

SPECIFICATION

P-37 E-17,22,24 U-type E-22

+++-

+-

32E8

+-

+-

32E3

+-

+-

32E4

+-

+-

++-

+-

+-

+-

+-

+-

+-

+-

+-

+-

+-

++-

PRE-SET PRE-SET

(1.0 turn back) (1

Va

turns back)

++-

+++-

E-18

+-

+-

32E2

1 500± 50 r/min.

+-

# 137.5

6H21-4th

+-

+-

+-

+-

PRE-SET

(1.0 turn back)

+-

+-

ELECTRICAL

ITEM

Ignition timing

Spark plug

Gap

SPECIFICATION

10° B.T.D.C. at 1 500 r/min.

Type

NO.: U31ESR-N

N.G.K.: CR10E

0.7-0.8

(0.028-0.031 )

Primary

Over 8 (0.3) at 1 atm.

0.07-0.12 n

Spark performance

Ignition coil resistance

Generator coil resistance

Generator no-load voltage

Generator Max. output

Regulated voltage

Starter relay resistance

Battery Type designation

Capacity

Fuse size

Standard electrolyte S.G.

Main

Headlight (H)

Headlight (L)

Secondary 23-25 kn

Charging 0.5-0.9 n

Power source 0.1-0.2 n

Pick-up 170-256 n

More than 75 V(AC) at 5 000 r/min.

Approx. 200W at 5000 r/min.

13:0-16.0 V at 5 000 r/min.

3-5 n

YTX9-BS

12V 28.8 kC (8Ah)/1 0 HR

1.320 at 20°C (68°F)

30 A

10 A

10 A

WATTAGE

ITEM

Headlight

Parking or position light

I HI

I

La

Tail/Brake light

Turn signal light

Speedometer light

Turn signal indicator light

High beam indicator light

Neutral indicator light

License light

BRAKE

+

WHEEL

ITEM

Rear brake pedal height

Brake disc thickness

Brake disc runout

Front

Rear

STANDARD

5

(0.2)

4.0,

(0.157

± 0.2

± 0.008)

4.5

(0.177

± 0.2

± 0.008)

- -

Unit: mm (in)

NOTE

B-B/W

Plug cap-

Plug cap y-y

B-W

BI-G

E-03,24,28,33

SPECIFICATION

Other markets

60

55

+-

+-

4

5/21

21

3

2

2

2

5

+-

+-

+-

+-

+-

+-

+-

Unit:W

Unit: mm (in)

LIMIT

- -

3.5

(0.14)

4.0

(0.16)

0.30

( 0.012 )

9-8

g.g

ITEM

Master cylinder bore

Master cylinder piston diam.

Brake caliper cylinder bore

Brake caliper piston diam.

Wheel rim runout

Wheel axle runout

Tire rim size

Tire size

Tire tread depth

Front

Rear

Front

Rear

Front

Rear

Front

Rear

Axial

Radial

Front

Rear

Front

Rear

Front

Rear

Front

Rear

SUSPENSION

ITEM

Front fork stroke

Front fork spring free length

Front fork oil level

STANDARD

260

(10.2)

220

(8.7)

- -

164

(6.5)

150

(5.9)

STANDARD

12.700-12.743

(0.5000-0.5017)

12.700-12.743

(0.5000-0.5017)

12.657 -12.684

(0.4983-0.4994)

12.657-12.684

(0.4983-0.4994)

27.000-27.050

(1.0630-1.0650)

30.23-30.28

(1.1902 -1.1921)

26.90-26.95

(1.0591-1.0610)

30.16-30.18

(1.1874-1.1882)

- -

- -

- -

- -

J21 x 1.85

J17 x MT2.50

90/90-21 545

120/90-1 7 645

- -

- -

LIMIT

- -

- -

548

(21.6)

- -

- -

LIMIT

- -

- -

- -

- -

- -

- -

- -

- -

2.0

(0.08)

2.0

(0.08)

0.25

(0.010)

0.25

(0.010)

- -

- -

- -

- -

3.0

(0.12)

3.0

(0.12)

Unit: mm (in)

NOTE

Low seat

Low seat

ITEM

Rear shock absorber spring pre-set length

Rear wheel travel

Swingarm pivot shaft runout

STANDARD

247.5

(9.74)

260

(10.2)

220

(8.7)

- -

LIMIT

- -

- -

- -

0.3

(0.01)

NOTE

Low seat

TIRE PRESSURE

COLD INFLATION

TIRE PRESSURE

FRONT

REAR

SOLO RIDING DUAL RIDING kPa kg/cm2 psi kPa kg/cm2 psi

150 1.50 22 175 1.75 25

175 1.75 25 200 2.00 29

FUEL+OIL

Fuel type

ITEM

Fuel tank capacity

Engine oil type

Engine oil capacity

Front fork oil type

Front fork oil capacity (each leg)

Brake fluid type

SPECIFICATION

Use only unleaded gasoline of at least 87 pump octane (R; M) or 91 octane or higher rated by the research method.

Gasoline containing MTBE (Methyl Tertiary

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

Use only unleaded gasoline of at least 87 pump octane ( R; M method) or 91 octane or higher rated by the Research Method.

NOTE

E-03,33

E-28

Gasoline used should be graded 85-95 octane or higher. An unleaded gasoline is Other markets recommended.

Including reserve

12 L

(3.2/2.6 US/Imp gal)

13 L

(3.4/2.9 US/Imp gal)

E-33

Other markets

Only reserve

3.0 L

(0.8/0.7 US/Imp gal)

SAE 10W/40, API SF or SG

Oil change

Oil and filter change

Engine overhaul

2 300 ml

(2.4/2.0 US/Imp qt)

2400 ml

(2.5/2.1 US/Imp qt)

2 600 ml

(2.7/2.3 US/Imp qt)

Fork oil # 10

565 ml

(19.1/19.9 US/Imp oz)

563 ml

(19.0/19.8 US/Imp oz)

DOT 4

Low seat

9·10

SPEEDOMETER

;

FRONT TURN SIGNAL LIGHT (RI t:;:h-O-ff'!-.Lg-

\:;fJB/Wq}B/W

IGNITION COIL

0 _

III

j

j >, o • •

~

* "

I al

I to I

I jjj III j

.,o-J

00

I

~

I ) :

> rw

;;: i!i

. [

HEADLIGHT

~rw

OB~w

@Jo~$W

FRONT TURN SIGNAL LIGHT ILl

I

I

L

II r

Lbl 0

II

TURN SIGNAL

LIGHT SWITCH

ENGINE

KILL

SWITCH

FRONT

BRAKE

SWITCH

STARTER

BUTTON

R'UN'=

'OFF! !

~

J~'PUSHIM'

I I

COl UNIT

11 III I a'P ~~~ a

I

SIDE STAND

SWITCH

ON

OFF

G 61

Wn#

"

.,

REAR BRAKE

SWITCH

TURIlo

~ ~~~~~~~L

STAND

~~-

1m 9~

ij

o ;;: fl

., j

REAR TURN SI

~/~W®

O/W IW

W/OWw/O

TAILIBRAKE LIGHT '@

~~o~w®

LICENSE LIGHT

O~wO;~W®

REAR TURN SIGNAL LIGHT (LI u)

00

I s:

0 c m r-

"'0 lJ

0

C c:

(")

::!

0 z

-

0

2:

» z c

»

."

-t m lJ

C l>

C)

:a l> s:

-

:E

I!

:a

2

C)

M

HORN

HI

LO iii

I W Y

P

LOCK

DIMMER

SWITCH

OFF

ON

IGNITION SWITCH

ON

V/G VI

FF

CLUTCH

LEVER

~~~~~~N

~ f

WIRE COLOR

B Black

BI Blue

~~ g~ g;:~nn

Lbl lighl blue

~""To:!:"I=

I-O"'F=F!'f-"CP;~

(j) '"

,,~;;:

Lg

0 lighl green

Orange · ,)nr\lli1~,"u'

'.".

~

0/.:::

~

.1 :

2 .

HEADLIGHT IHI)

HEADLIGHT ILO)

BIBI

BILg

Black wilh Blue Iracer

Black wilh lighl green tracer

BIO Black wilh Orange tracer

M ON

NEUTRAL REGULATORI GENERATOR

SWITCH RECTIFIER

BIR

BIW

BIIB

Black wilh Red Iracer

Black wilh While tracer

Blue wilh Black Iracer

F: MAIN FUSE

M: STARTER MOTOR

BIIW : Blue wilh While tracer

GIBI

O/W

DIY

Green Wllh Blue tracer

Orange with White tracer

Orange with Yellow tracer

RIB

WIB

Red wilh Black tracer

While wilh Black tracer

W IBI : While wilh Blue tracer

Yellow wilh Black Iracer

Y/G

YIW

Yellow with Green tracer

Yellow wilh While Iracer

DR650SEK1 (’01-MODEL)

CONTENTS

SPECIFICATIONS .............................................................................. 10- 1

SERVICE DATA .................................................................................. 10- 2

LIQUID GASKET ................................................................................ 10- 10

10

10-1 DR650SEK1 (’01-MODEL)

SPECIFICATIONS

DIMENSIONS AND DRY MASS

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

2 345 mm (92.3 in) ….. E-17, 28, 22

2 325 mm (91.5 in) ….. E-17, 28, 22 (Low seat)

2 255 mm (88.8 in) ….. Others

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

2 235 mm (88.0 in) ….. Others (Low seat)

865 mm (34.1 in)

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

1 205 mm (47.4 in)

1 165 mm (45.9 in) ….. (Low seat)

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

1 490 mm (58.7 in)

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

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

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

1 475 mm (58.1 in) ….. (Low seat)

265 mm (10.4 in)

225 mm ( 8.9 in) ….. (Low seat)

885 mm (34.8 in)

845 mm (33 in) ….. (Low seat)

147 kg (324 lbs)

ENGINE

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

Four-stroke, air-cooled, OHC

Valve clearance (IN) ................................................................

0.08 – 0.13 mm (0.003 – 0.005 in)

(EX) ...............................................................

0.17 – 0.22 mm (0.007 – 0.009 in)

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

1

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

100 mm (3.937 in)

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

82 mm (3.228 in)

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

644 cm 3 (39.3 cu. in)

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

9.5 : 1

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

MIKUNI BST40SS, single

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

Polyurethane foam element

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

Electric

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

Wet sump

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

1 500 ± 100 r/min

TRANSMISSION

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

Wet multi-plate type

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

5-speed constant mesh

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

1-down, 4-up

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

2.178 (61/28)

Gear ratios, Low .......................................................................

2.416 (29/12)

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

1.625 (26/16)

3rd .........................................................................

1.238 (26/21)

4th .........................................................................

1.000 (21/21)

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

0.826 (19/23)

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

2.800 (42/15) ….. E-03, 28, 33

2.733 (41/15) ….. Others

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

DID 525 V8, 110 links

CHASSIS

Front suspension ......................................................................

Telescopic, coil spring, oil damped

Rear suspension ......................................................................

Link type, coil spring, oil damped, spring preload fully adjustable, compression damping force adjustable

Front fork stroke .......................................................................

260 mm (10.2 in)

220 mm ( 8.7 in) ….. (Low seat)

Rear wheel travel .....................................................................

260 mm (10.2 in)

220 mm ( 8.7 in) ….. (Low seat)

Steering angle ..........................................................................

43°

Caster .......................................................................................

28° 30’

Trail ...........................................................................................

111 mm (4.37 in)

Turning radius ...........................................................................

2.5 m (8.2 ft)

Front brake ...............................................................................

Disc brake

Rear brake ................................................................................

Disc brake

Front tire size ............................................................................

90/90-21 54S, tube type

Rear tire size ............................................................................

120/90-17 64S, tube type

ELECTRICAL

Ignition type ..............................................................................

Electronic ignition (CDI)

Ignition timing ...........................................................................

10° B.T.D.C. at 1 500 rpm

Spark plug ................................................................................

NGK CR10E or DENSO U31ESR-N

Battery ......................................................................................

12V 28.8 kC (8 Ah)/10HR

Generator .................................................................................

Three-phase A.C. generator

Main fuse ..................................................................................

30A

Fuse ..........................................................................................

10/10A

Headlight ..................................................................................

12V 60/55W

Parking or city light ...................................................................

12V 4W ….. Except E-03, 24, 28, 33

Turn signal light ........................................................................

12V 21W

Brake light/Taillight ...................................................................

12V 21/5W

License plate light ....................................................................

12V 5W

Speedometer light ....................................................................

12V 1.7W

Neutral indicator light ...............................................................

12V 2W

High beam indicator light .........................................................

12V 2W

Turn signal indicator light .........................................................

12V 2W

CAPACITIES

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

12.0 L (3.2/2.6 US/Imp gal) ….. E-33

13.0 L (3.4/2.9 US/Imp gal) ….. Others reserve ....................................................................

3.0 L (0.8/0.7 US/Imp gal)

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

2 300 ml (2.4/2.0 US/Imp qt) with filter change ....................................................

2 400 ml (2.5/2.1 US/Imp qt) overhaul ..................................................................

2 600 ml (2.7/2.3 US/Imp qt)

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

565 ml (19.1/19.9 US/Imp oz)

563 ml (19.0/19.8 US/Imp oz) ….. (Low seat)

SERVICE DATA

VALVE + GUIDE

ITEM

Valve diam.

Valve clearance

(when engine is cold)

Valve guide to valve stem clearance

Valve stem deflection

Valve guide I.D.

Valve stem O.D.

Valve stem runout

Valve head thickness

Valve stem end length

Valve seat width

Valve head radial runout

Valve spring free length

(IN. & EX.)

Valve spring tension (IN. & EX.)

IN.

EX.

IN. & EX.

IN. & EX.

IN. & EX.

IN. & EX.

IN. & EX.

INNER

OUTER

IN.

EX.

IN.

EX.

IN.

EX.

IN. & EX.

IN. & EX.

INNER

OUTER

STANDARD

33

(1.3)

28

(1.1)

0.08 – 0.13

(0.003 – 0.005)

0.17 – 0.22

(0.0067 – 0.0087)

0.010 – 0.037

(0.0004 – 0.0015)

0.030 – 0.057

(0.0012 – 0.0022)

———

5.500 – 5.512

(0.2165 – 0.2170)

5.475 – 5.490

(0.2156 – 0.2161)

5.455 – 5.470

(0.2148 – 0.2154)

———

———

———

0.9 – 1.1

(0.035 – 0.043)

———

———

———

5.9 – 6.7 kg

(13.0 – 14.8 lbs) at length 27.5 mm (1.1 in)

13.8 – 15.8 kg

(30.4 – 34.8 lbs) at length 31.0 mm (1.2 in)

DR650SEK1 (’01-MODEL) 10-2

Unit: mm (in)

LIMIT

———

———

———

———

———

———

0.35

(0.014)

———

———

———

0.05

(0.002)

0.5

(0.02)

2.7

(0.11)

———

0.03

(0.001)

34.4

(1.35)

38.1

(1.50)

———

———

10-3 DR650SEK1 (’01-MODEL)

CAMSHAFT + CYLINDER HEAD

ITEM

Cam height

IN.

Camshaft journal oil clearance

Camshaft journal holder I.D.

Camshaft journal O.D.

EX.

Right &

Center

Left

Right &

Center

Left

Right &

Center

Left

Camshaft runout

Rocker arm I.D.

Rocker arm shaft O.D.

Cylinder head distortion

Cylinder head cover distortion

IN. & EX.

IN. & EX.

STANDARD

33.710 – 33.750

(1.3272 – 1.3287)

33.700 – 33.740

(1.3268 – 1.3283)

0.032 – 0.066

(0.0013 – 0.0026)

0.028 – 0.059

(0.0011 – 0.0023)

22.012 – 22.025

(0.8666 – 0.8671)

17.512 – 17.525

(0.6894 – 0.6900)

21.959 – 21.980

(0.8645 – 0.8654)

17.466 – 17.484

(0.6877 – 0.6883)

———

12.000 – 12.018

(0.4724 – 0.4731)

11.973 – 11.984

(0.4714 – 0.4718)

———

———

CYLINDER + PISTON + PISTON RING

ITEM

Piston to cylinder clearance

Cylinder bore

Piston diam.

STANDARD

0.020 – 0.030

(0.0008 – 0.0012)

100.000 – 100.015

(3.9371 – 3.9376)

99.975 – 99.990

(3.9360 – 3.9366)

Measure at 21 mm (0.8 in) from the skirt end.

Cylinder distortion

———

Piston ring free end gap

1st R

Piston ring end gap

Compression pressure

(Automatic decomp. actuated)

2nd R

1st

2nd

Approx.

13.5

(0.53)

Approx.

11.4

(0.45)

0.30 – 0.45

(0.012 – 0.018)

0.45 – 0.60

(0.018 – 0.024)

850 kPa

Approx. ( 8.5 kg/cm 2 )

———

0.10

(0.004)

———

———

0.05

(0.002)

0.05

(0.002)

Unit: mm (in)

LIMIT

33.410

(1.3154)

33.400

(1.3150)

0.150

(0.0059)

0.150

(0.0059)

———

———

———

Unit: mm (in)

LIMIT

0.120

(0.0047)

Nicks or

Scratches

99.880

(3.9323)

0.05

(0.002)

10.8

(0.43)

9.1

(0.36)

0.50

(0.020)

1.00

(0.039)

———

ITEM

Piston ring to groove clearance

Piston ring groove width

Piston ring thickness

Piston pin bore

Piston pin O.D.

CONROD + CRANKSHAFT

ITEM

Conrod small end I.D.

Conrod deflection

Conrod big end side clearance

Conrod big end width

Crankshaft runout

Crank web to web width

OIL PUMP

ITEM

Oil pump reduction ratio

Oil pressure (at 60°C,140°F)

Oil

1st

2nd

1st

2nd

1st

2nd

STANDARD

1.633 (61/28 × 30/20 × 15/30)

Above 30 kPa (0.3 kg/cm 2 , 4.3 psi)

Below 70 kPa (0.7 kg/cm 2 , 10.0 psi) at 3 000 r/min.

STANDARD

———

———

1.230 – 1.250

(0.048 – 0.049)

1.210 – 1.230

(0.047 – 0.048)

2.810 – 2.830

(0.110 – 0.111)

1.170 – 1.190

(0.0461 – 0.0469)

1.150 – 1.170

(0.0453 – 0.0461)

23.002 – 23.008

(0.9056 – 0.9058)

22.996 – 23.000

(0.9054 – 0.9055)

STANDARD

23.006 – 23.014

(0.9057 – 0.9061)

———

0.10 – 0.65

(0.004 – 0.026)

24.95 – 25.00

(0.982 – 0.984)

———

71.0 ± 0.1

(2.795 ± 0.004)

DR650SEK1 (’01-MODEL) 10-4

LIMIT

0.180

(0.0071)

0.150

(0.0059)

———

———

———

———

———

23.030

(0.9067)

22.980

(0.9047)

Unit: mm (in)

LIMIT

23.040

(0.9071)

3.0

(0.12)

1.00

(0.039)

———

0.05

(0.002)

———

LIMIT

———

———

10-5 DR650SEK1 (’01-MODEL)

CLUTCH

ITEM

Clutch lever play

Drive plate thickness

Driven plate distortion

Clutch spring free length

No.1 &

No.2

STANDARD

10 – 15

(0.4 – 0.6)

2.9 – 3.1

(0.11 – 0.12)

———

———

Unit: mm (in)

LIMIT

———

2.6

(0.10)

0.10

(0.004)

33.0

(1.30)

TRANSMISSION + DRIVE CHAIN

ITEM

Primary reduction ratio

Final reduction ratio

E-03,28,33

The others

Gear ratios Low

2nd

3rd

4th

Top

Shift fork to groove clearance

Shift fork groove width

Shift fork thickness

Drive chain Type

Links

20-pitch length

STANDARD

2.178 (61/28)

2.800 (42/15)

2.733 (41/15)

2.416 (29/12)

1.625 (26/16)

1.238 (26/21)

1.000 (21/21)

0.826 (19/23)

0.10 – 0.30

(0.004 – 0.012)

5.0 – 5.1

(0.197 – 0.200)

4.8 – 4.9

(0.189 – 0.193)

DAIDO:DID525V8

110

———

Drive chain slack 30 – 45

(1.2 – 1.8)

Unit: mm (in) Except ratio

LIMIT

———

———

———

———

———

———

———

———

0.50

(0.020)

———

———

———

———

319.4

(12.57)

———

DR650SEK1 (’01-MODEL) 10-6

CARBURETOR

ITEM

Carburetor type

Bore size

I.D. No.

Idle r/min.

Float height

Main jet

Jet needle

Needle jet

Throttle valve

Pilot jet

Starter jet

Pilot screw

Throttle cable play

(pulling cable)

Starter cable play

CARBURETOR

ITEM

Carburetor type

Bore size

I.D. No.

Idle r/min.

Float height

Main jet

Jet needle

Needle jet

Throttle valve

Pilot jet

Starter jet

Pilot screw

Throttle cable play

(pulling cable)

Starter cable play

(M.J.)

(J.N.)

(N.J.)

(Th.V.)

(P.J.)

(G.S.)

(P.S.)

E-03, 28

MIKUNI

BST40SS

40 mm

32E1

1 500 ± 100 r/min.

14.7 ± 1.0 mm

(0.58 ± 0.04in)

#

6F23

#95

#

#40

PRE-SET

0.5 – 1.0 mm

(0.02 – 0.04 in)

0.5 – 1.0 mm

(0.02 – 0.04 in)

SPECIFICATION

E-33

←

←

32E6

←

←

←

←

←

←

←

←

←

←

E-18

←

←

32E2

1 500 ± 50 r/min.

←

#137.5

6H21-4th

←

←

←

PRE-SET

(1.0 turn back)

←

←

(M.J.)

(J.N.)

(N.J.)

(Th.V.)

(P.J.)

(G.S.)

(P.S.)

E-04, 34, 54

MIKUNI BST40SS

40 mm

32E0

1 500 ± 100 r/min.

14.7 ± 1.0 mm

(0.58 ± 0.04 in)

#140

6F19-3rd

Y-5

#95

#42.5

#40

PRE-SET

(1½ turns back)

0.5 – 1.0 mm

(0.02 – 0.04 in)

0.5 – 1.0 mm

(0.02 – 0.04 in)

SPECIFICATION

E-17, 22, 24

←

←

32E3

←

←

←

←

←

←

←

←

PRE-SET

(1.0 turn back)

←

←

U-type E-22

←

←

32E4

←

←

←

←

←

←

←

←

(1 1

PRE-SET

/

8

turns back)

←

←

10-7 DR650SEK1 (’01-MODEL)

ELECTRICAL

Ignition timing

Spark plug

ITEM

Spark performance

Ignition coil resistance

Generator coil resistance

Generator no-load voltage

Generator Max. output

Regulated voltage

Starter relay resistance

Battery Type designation

Capacity

Standard electrolyte S.G.

Fuse size Main

Headlight (H)

Headlight (L)

WATTAGE

ITEM

Headlight HI

LO

Parking or position light

Brake light/Taillight

Turn signal light

Speedometer light

Turn signal indicator light

High beam indicator light

Neutral indicator light

License light

BRAKE + WHEEL

ITEM

Rear brake pedal height

Brake disc thickness

Brake disc runout

Type

Gap

Primary

SPECIFICATION

10° B.T.D.C. at 1 500 r/min.

ND.: U31ESR-N

N.G.K.: CR10E

Secondary

0.7 – 0.8

(0.028 – 0.031)

Over 8 (0.3) at 1 atm.

0.07 – 0.12

Ω

23 – 25 k

Ω

Charging

Power source

Pick-up

0.5 – 0.9

Ω

0.1 – 0.2

Ω

170 – 256

Ω

More than 75 V (AC) at 5 000 r/min.

Approx. 200 W at 5 000 r/min.

13.0 – 16.0 V at 5 000 r/min.

3 – 5

Ω

YTX9-BS

12V 28.8 kC (8Ah)/10 HR

1.320 at 20°C (68°F)

30 A

10 A

10 A

Unit: mm (in)

NOTE

B – B/W

Plug cap –

Plug cap

Y – Y

B – W

Bl – G

Unit: W

Front

Rear

E-03, 24, 28, 33

60

55

SPECIFICATION

5/21

21

3

2

2

2

5

Other markets

←

←

4

←

←

←

←

←

←

←

STANDARD

5

(0.2)

4.0 ± 0.2

(0.157 ± 0.008)

4.5 ± 0.2

(0.177 ± 0.008)

———

Unit: mm (in)

LIMIT

———

3.5

(0.14)

4.0

(0.16)

0.30

(0.012)

ITEM

Master cylinder bore

Master cylinder piston diam.

Brake caliper cylinder bore

Brake caliper piston diam.

Wheel rim runout

Wheel axle runout

Tire rim size

Tire size

Tire tread depth

SUSPENSION

ITEM

Front fork stroke

Front fork spring free length

Front fork oil level

Front

Rear

Front

Rear

Front

Rear

Front

Rear

Axial

Radial

Front

Rear

Front

Rear

Front

Rear

Front

Rear

STANDARD

260

(10.2)

220

(8.7)

———

164

(6.5)

150

(5.9)

STANDARD

12.700 – 12.743

(0.5000 – 0.5017)

12.700 – 12.743

(0.5000 – 0.5017)

12.657 – 12.684

(0.4983 – 0.4994)

12.657 – 12.684

(0.4983 – 0.4994)

27.000 – 27.050

(1.0630 – 1.0650)

30.23 – 30.28

(1.1902 – 1.1921)

26.90 – 26.95

(1.0591 – 1.0610)

30.16 – 30.18

(1.1874 – 1.1882)

———

———

———

———

J21 × 1.85

J17 × MT2.50

90/90-21 54S

120/90-17 64S

———

———

LIMIT

———

———

548

(21.6)

———

———

DR650SEK1 (’01-MODEL) 10-8

LIMIT

———

———

———

———

———

———

———

———

2.0

(0.08)

2.0

(0.08)

0.25

(0.010)

0.25

(0.010)

———

———

———

———

3.0

(0.12)

3.0

(0.12)

Unit: mm (in)

NOTE

Low seat

Low seat

10-9 DR650SEK1 (’01-MODEL)

ITEM

Rear shock absorber spring pre-set length

Rear wheel travel

Swingarm pivot shaft runout

STANDARD

247.5

(9.74)

260

(10.2)

220

(8.7)

———

LIMIT

———

———

———

0.3

(0.01)

TIRE PRESSURE

COLD INFLATION SOLO RIDING

TIRE PRESSURE kPa kg/cm 2 psi

FRONT 150 1.50

22

REAR 175 1.75

25

FUEL + OIL

ITEM

Fuel type

DUAL RIDING kPa kg/cm 2

175 1.75

psi

25

200 2.00

29

SPECIFICATION

Use only unleaded gasoline of at least 87 pump

Fuel tank capacity

Engine oil type

Engine oil capacity

Front fork oil type

Front fork oil capacity (each leg)

Brake fluid type

NOTE

Low seat

NOTE research method.

Gasoline containing MTBE (Methyl Tertiary Butyl

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

Gasoline used should be graded 85-95 octane or higher. An unleaded gasoline is recommended.

Including reserve

12 L

(3.2/2.6 US/Imp gal)

13 L

(3.4/2.9 US/Imp gal)

Only reserve

3.0 L

(0.8/0.7 US/Imp gal)

Oil change

SAE 10W/40, API SF or SG

2 300 ml

(2.4/2.0 US/lmp qt)

Oil and filter change

2 400 ml

(2.5/2.1 US/lmp qt)

Engine overhaul

2 600 ml

(2.7/2.3 US/lmp qt)

Fork oil #10

565 ml

(19.1/19.9 US/lmp oz)

563 ml

(19.0/19.8 US/Imp oz)

DOT 4

E-03, 28, 33

Other markets

E-33

Other markets

Low seat

LIQUID GASKET

CYLINDER HEAD COVER

DR650SEK1 (’01-MODEL) 10-10

NOTE:

SUZUKI BOND NO.1215 or NO.1207B has to be applied to the cylinder head cover and cylinder head.

CYLINDER HEAD

 

DR650SEK2/K3/K4/K5/K6/K7 (’02/’03/’04/’05/’06/’07/’08-MODELS) 11-1

DR650SEK2/K3/K4/K5 /K6/K7 (’02/’03/’04/’05/’06/’07 /’08-MODELS)

CONTENTS

SPECIFICATIONS.............................................................................. 11- 2

SERVICE DATA .................................................................................. 11- 3

11

SPECIFICATIONS

DIMENSIONS AND DRY MASS

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

2 345 mm (92.3 in) ….. E-17, 28

2 325 mm (91.5 in) ….. E-17, 28 (Low seat)

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

2 255 mm (88.8 in) ….. Others

2 235 mm (88.0 in) ….. Others (Low seat)

865 mm (34.1 in)

Overall height ........................................................................... * 1 195 mm (47.0 in)

* 1 155 mm (45.5 in) ….. (Low seat)

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

1 490 mm (58.7 in)

1 475 mm (58.1 in) ….. (Low seat)

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

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

265 mm (10.4 in)

225 mm ( 8.9 in) ….. (Low seat)

885 mm (34.8 in)

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

845 mm (33 in) ….. (Low seat)

147 kg (324 lbs)

ENGINE

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

Four-stroke, air-cooled, OHC

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

1

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

100 mm (3.937 in)

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

82 mm (3.228 in)

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

644 cm 3 (39.3 cu. in)

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

9.5 : 1

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

MIKUNI BST40SS, single

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

Polyurethane foam element

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

Electric

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

Wet sump

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

1 500 ± 100 r/min

DRIVE TRAIN

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

Wet multi-plate type

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

5-speed constant mesh

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

1-down, 4-up

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

2.178 (61/28)

Gear ratios, Low ......................................................................

2.416 (29/12)

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

1.625 (26/16)

3rd .......................................................................

1.238 (26/21)

4th .......................................................................

1.000 (21/21)

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

0.826 (19/23)

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

2.800 (42/15) ….. E-03, 28, 33

2.733 (41/15) ….. Others

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

DID 525 V8, 110 links

CHASSIS

Front suspension ......................................................................

Telescopic, coil spring, oil damped

Rear suspension ......................................................................

Link type, coil spring, oil damped

Front fork stroke .......................................................................

260 mm (10.2 in)

220 mm ( 8.7 in) ….. (Low seat)

Rear wheel travel .....................................................................

260 mm (10.2 in)

220 mm ( 8.7 in) ….. (Low seat)

Steering angle ..........................................................................

43°

Caster .......................................................................................

28° 30’

Trail ...........................................................................................

111 mm (4.37 in)

Turning radius ...........................................................................

2.5 m (8.2 ft)

Front brake ...............................................................................

Disk brake

Rear brake ................................................................................

Disk brake

Front tire size ............................................................................

90/90-21 M/C 54S, tube type

Rear tire size ............................................................................

120/90-17 M/C 64S, tube type

ELECTRICAL

Ignition type ..............................................................................

Electronic ignition (CDI)

Ignition timing ...........................................................................

10° B.T.D.C. at 1 500 rpm

Spark plug ................................................................................

NGK CR10E or DENSO U31ESR-N

Battery ......................................................................................

12V 28.8 kC (8 Ah)/10HR

Generator .................................................................................

Three-phase A.C. generator

Main fuse ..................................................................................

30A

Fuse ..........................................................................................

10/10A

Headlight ..................................................................................

12V 60/55W

Parking or city light ...................................................................

12V 4W ….. Except E-03, 24, 28, 33

Turn signal light ........................................................................

12V 21W

Brake light/Taillight ...................................................................

12V 21/5W

License plate light ....................................................................

12V 5W

Speedometer light ....................................................................

12V 1.7W

Neutral indicator light ...............................................................

12V 2W

High beam indicator light .........................................................

12V 2W

Turn signal indicator light .........................................................

12V 2W

CAPACITIES

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

12.0 L (3.2/2.6 US/Imp gal) ….. E-33 reserve .....................................................................

13.0 L (3.4/2.9 US/Imp gal) ….. Others

3.0 L (0.8/0.7 US/Imp gal)

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

2 300 ml (2.4/2.0 US/Imp qt) with filter change ....................................................

2 400 ml (2.5/2.1 US/Imp qt) overhaul .................................................................

2 600 ml (2.7/2.3 US/Imp qt)

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

565 ml (19.1/19.9 US/Imp oz)

563 ml (19.0/19.8 US/lmp oz)

DR650SEK2/K3/K4/K5/K6/K7 (’02/’03/’04/’05/’06/’07/’08-MODELS) 11-3 3

SERVICE DATA

VALVE + GUIDE

ITEM

Valve diam.

Valve clearance

(when engine is cold)

Valve guide to valve stem clearance

Valve stem deflection

Valve guide I.D.

Valve stem O.D.

Valve stem runout

Valve head thickness

Valve stem end length

Valve seat width

Valve head radial runout

Valve spring free length

(IN. & EX.)

Valve spring tension (IN. & EX.)

IN.

EX.

IN. & EX.

IN. & EX.

IN. & EX.

IN. & EX.

IN. & EX.

INNER

OUTER

IN.

EX.

IN.

EX.

IN.

EX.

IN. & EX.

IN. & EX.

INNER

OUTER

STANDARD

33

(1.3)

28

(1.1)

0.08 – 0.13

(0.003 – 0.005)

0.17 – 0.22

(0.0067 – 0.0087)

0.010 – 0.037

(0.0004 – 0.0015)

0.030 – 0.057

(0.0012 – 0.0022)

———

5.500 – 5.512

(0.2165 – 0.2170)

5.475 – 5.490

(0.2156 – 0.2161)

5.455 – 5.470

(0.2148 – 0.2154)

———

———

———

0.9 – 1.1

(0.035 – 0.043)

———

———

———

5.9 – 6.7 kg

(13.0 – 14.8 lbs) at length 27.5 mm (1.1 in)

13.8 – 15.8 kg

(30.4 – 34.8 lbs) at length 31.0 mm (1.2 in)

Unit: mm (in)

LIMIT

———

———

———

———

———

———

0.35

(0.014)

———

———

———

0.05

(0.002)

0.5

(0.02)

2.7

(0.11)

———

0.03

(0.001)

34.4

(1.35)

38.1

(1.50)

———

———

11-4 DR650SEK2/K3/K4/K5/K6/K7 (’02/’03/’04/’05/’06/’07/’08-MODELS)

CAMSHAFT + CYLINDER HEAD

ITEM

Cam height

IN.

Camshaft journal oil clearance

Camshaft journal holder I.D.

Camshaft journal O.D.

EX.

Right &

Center

Left

Right &

Center

Left

Right &

Center

Left

Camshaft runout

Rocker arm I.D.

Rocker arm shaft O.D.

Cylinder head distortion

Cylinder head cover distortion

IN. & EX.

IN. & EX.

STANDARD

33.710 – 33.750

(1.3272 – 1.3287)

33.700 – 33.740

(1.3268 – 1.3283)

0.032 – 0.066

(0.0013 – 0.0026)

0.028 – 0.059

(0.0011 – 0.0023)

22.012 – 22.025

(0.8666 – 0.8671)

17.512 – 17.525

(0.6894 – 0.6900)

21.959 – 21.980

(0.8645 – 0.8654)

17.466 – 17.484

(0.6877 – 0.6883)

———

12.000 – 12.018

(0.4724 – 0.4731)

11.973 – 11.984

(0.4714 – 0.4718)

———

———

CYLINDER + PISTON + PISTON RING

ITEM

Piston to cylinder clearance

Cylinder bore

Piston diam.

STANDARD

0.020 – 0.030

(0.0008 – 0.0012)

100.000 – 100.015

(3.9371 – 3.9376)

99.975 – 99.990

(3.9360 – 3.9366)

Measure at 21 mm (0.8 in) from the skirt end.

Cylinder distortion

———

Piston ring free end gap

1st R

Piston ring end gap

Compression pressure

(Automatic decomp. actuated)

2nd R

1st

2nd

Approx.

13.5

(0.53)

Approx.

11.4

(0.45)

0.30 – 0.45

(0.012 – 0.018)

0.45 – 0.60

(0.018 – 0.024)

850 kPa

Approx. ( 8.5 kg/cm 2 )

———

0.10

(0.004)

———

———

0.05

(0.002)

0.05

(0.002)

Unit: mm (in)

LIMIT

33.410

(1.3154)

33.400

(1.3150)

0.150

(0.0059)

0.150

(0.0059)

———

———

———

Unit: mm (in)

LIMIT

0.120

(0.0047)

Nicks or

Scratches

99.880

(3.9323)

0.05

(0.002)

10.8

(0.43)

9.1

(0.36)

0.50

(0.020)

1.00

(0.039)

———

ITEM

Piston ring to groove clearance

Piston ring groove width

Piston ring thickness

Piston pin bore

Piston pin O.D.

CONROD + CRANKSHAFT

ITEM

Conrod small end I.D.

Conrod deflection

Conrod big end side clearance

Conrod big end width

Crankshaft runout

Crank web to web width

Oil

1st

2nd

1st

2nd

1st

2nd

DR650SEK2/K3/K4/K5/K6/K7 (’02/’03/’04/’05/’06/’07/’08-MODELS) 11-5

STANDARD

———

———

1.230 – 1.250

(0.048 – 0.049)

1.210 – 1.230

(0.047 – 0.048)

2.810 – 2.830

(0.110 – 0.111)

1.170 – 1.190

(0.0461 – 0.0469)

1.150 – 1.170

(0.0453 – 0.0461)

23.002 – 23.008

(0.9056 – 0.9058)

22.996 – 23.000

(0.9054 – 0.9055)

STANDARD

23.006 – 23.014

(0.9057 – 0.9061)

———

0.10 – 0.65

(0.004 – 0.026)

24.95 – 25.00

(0.982 – 0.984)

———

71.0 ± 0.1

(2.795 ± 0.004)

LIMIT

0.180

(0.0071)

0.150

(0.0059)

———

———

———

———

———

23.030

(0.9067)

22.980

(0.9047)

Unit: mm (in)

LIMIT

23.040

(0.9071)

3.0

(0.12)

1.00

(0.039)

———

0.05

(0.002)

———

OIL PUMP

ITEM

Oil pump reduction ratio

Oil pressure (at 60°C,140°F)

STANDARD

1.633 (61/28

×

30/20

×

15/30)

Above 30 kPa (0.3 kg/cm 2 , 4.3 psi)

Below 70 kPa (0.7 kg/cm 2 , 10.0 psi) at 3 000 r/min.

LIMIT

———

———

11-6 DR650SEK2/K3/K4/K5/K6/K7 (’02/’03/’04/’05/’06/’07/’08-MODELS)

CLUTCH

ITEM

Clutch lever play

Drive plate thickness

Driven plate distortion

Clutch spring free length

DRIVE TRAIN

ITEM

Primary reduction ratio

Final reduction ratio

E-03,28,33

The others

Gear ratios Low

2nd

3rd

4th

Top

Shift fork to groove clearance

Shift fork groove width

Shift fork thickness

Drive chain

Drive chain slack

No.1 &

No.2

STANDARD

10 – 15

(0.4 – 0.6)

2.9 – 3.1

(0.11 – 0.12)

———

———

Unit: mm (in)

LIMIT

———

2.6

(0.10)

0.10

(0.004)

33.0

(1.30)

Type

Links

20-pitch length

STANDARD

2.178 (61/28)

2.800 (42/15)

2.733 (41/15)

2.416 (29/12)

1.625 (26/16)

1.238 (26/21)

1.000 (21/21)

0.826 (19/23)

0.10 – 0.30

(0.004 – 0.012)

5.0 – 5.1

(0.197 – 0.200)

4.8 – 4.9

(0.189 – 0.193)

DAIDO:DID525V8

110

———

30 – 45

(1.2 – 1.8)

Unit: mm (in) Except ratio

LIMIT

———

———

———

———

———

———

———

———

0.50

(0.020)

———

———

———

———

319.4

(12.57)

———

CARBURETOR

ITEM

Carburetor type

Bore size

I.D. No.

Idle r/min.

Float height

Main jet

Jet needle

Needle jet

Throttle valve

Pilot jet

Starter jet

Pilot screw

Throttle cable play

CARBURETOR

ITEM

Carburetor type

Bore size

I.D. No.

Idle r/min.

Float height

Main jet

Jet needle

Needle jet

Throttle valve

Pilot jet

Starter jet

Pilot screw

Throttle cable play

(M.J.)

(J.N.)

(N.J.)

(Th.V.)

(P.J.)

(G.S.)

(P.S.)

(M.J.)

(J.N.)

(N.J.)

(Th.V.)

(P.J.)

(G.S.)

(P.S.)

E-03, 28

MIKUNI

BST40SS

40 mm

32E1

1 500 ± 100 r/min.

14.7 ± 1.0 mm

(0.58 ± 0.04in)

#

6F23

#95

#

#40

PRE-SET

2.0 – 4.0 mm

(0.08 – 0.16 in)

SPECIFICATION

E-33

←

←

32E6

←

←

←

←

←

←

←

←

←

E-18

←

←

32E2

1 500 ± 50 r/min.

←

#137.5

6H21-4th

←

←

←

PRE-SET

(1.0 turn back)

←

E-04, 34

MIKUNI BST40SS

SPECIFICATION

40 mm

32E0

1 500 ± 100 r/min.

14.7 ± 1.0 mm

(0.58 ± 0.04 in)

#140

6F19-3rd

Y-5

#95

#42.5

#40

PRE-SET

(11⁄2 turns back)

2.0 – 4.0 mm

(0.08 – 0.16 in)

E-17, 24

←

←

32E3

←

←

←

←

←

←

←

←

PRE-SET

(1.0 turn back)

←

11-8 DR650SEK2/K3/K4/K5/K6/K7 (’02/’03/’04/’05/’06/’07/’08-MODELS)

ELECTRICAL

ITEM

Spark plug

Spark performance

Ignition coil resistance

Generator coil resistance

Generator no-load voltage

Generator Max. output

Regulated voltage

Starter relay resistance

Battery Type designation

Capacity

Standard electrolyte S.G.

Fuse size Main

Headlight (H)

Headlight (L)

WATTAGE

Headlight

ITEM

Parking or position light

Brake light/Taillight

Turn signal light

Speedometer light

Turn signal indicator light

High beam indicator light

Neutral indicator light

License light

BRAKE + WHEEL

ITEM

Rear brake pedal height

Brake disc thickness

Brake disc runout

HI

LO

Type

Gap

Primary

Secondary

SPECIFICATION

ND.: U31ESR-N

N.G.K.: CR10E

0.7 – 0.8

(0.028 – 0.031)

Over 8 (0.3) at 1 atm.

0.07 – 0.12

Ω

23 – 25 k

Ω

Charging

Power source

Pick-up

0.5 – 0.9

Ω

0.1 – 0.2

Ω

170 – 256

Ω

More than 75 V (AC) at 5 000 r/min.

Approx. 200 W at 5 000 r/min.

13.0 – 16.0 V at 5 000 r/min.

3 – 5

Ω

YTX9-BS

12V 28.8 kC (8Ah)/10 HR

1.320 at 20°C (68°F)

30 A

10 A

10 A

Front

Rear

E-03, 24, 28, 33

SPECIFICATION

60

55

5/21

21

1.7

2

5

2

2

STANDARD

5

(0.2)

4.0 ± 0.2

(0.157 ± 0.008)

4.5 ± 0.2

(0.177 ± 0.008)

———

Unit: mm (in)

NOTE

B – B/W

Plug cap –

Plug cap

Y – Y

B – W

Bl – G

Unit: W

Others

←

←

←

←

←

←

4

←

←

←

Unit: mm (in)

LIMIT

———

3.5

(0.14)

4.0

(0.16)

0.30

(0.012)

ITEM

Master cylinder bore

Master cylinder piston diam.

Brake caliper cylinder bore

Brake caliper piston diam.

Wheel rim runout

Wheel axle runout

Tire rim size

Tire size

Tire tread depth

SUSPENSION

ITEM

Front fork stroke

Front fork spring free length

Front fork oil level

Front

Rear

Front

Rear

Front

Rear

Front

Rear

Axial

Radial

Front

Rear

Front

Rear

Front

Rear

Front

Rear

STANDARD

260

(10.2)

220

(8.7)

———

164

(6.5)

150

(5.9)

STANDARD

12.700 – 12.743

(0.5000 – 0.5017)

12.700 – 12.743

(0.5000 – 0.5017)

12.657 – 12.684

(0.4983 – 0.4994)

12.657 – 12.684

(0.4983 – 0.4994)

27.000 – 27.050

(1.0630 – 1.0650)

30.23 – 30.28

(1.1902 – 1.1921)

26.90 – 26.95

(1.0591 – 1.0610)

30.16 – 30.18

(1.1874 – 1.1882)

———

———

———

———

21 × 1.85

17M/C × MT2.50

90/90-21M/C 54S

120/90-17M/C 64S

———

———

LIMIT

———

———

548

(21.6)

———

———

LIMIT

———

———

———

———

———

———

———

———

2.0

(0.08)

2.0

(0.08)

0.25

(0.010)

0.25

(0.010)

———

———

———

———

3.0

(0.12)

3.0

(0.12)

Unit: mm (in)

NOTE

Low seat

Low seat

11-10 DR650SEK2/K3/K4/K5/K6/K7 (’02/’03/’04/’05/’06/’07/’08-MODELS)

ITEM

Rear shock absorber spring pre-set length

Rear wheel travel

Swingarm pivot shaft runout

STANDARD

247.5

(9.74)

260

(10.2)

220

(8.7)

———

LIMIT

———

———

———

0.3

(0.01)

TIRE PRESSURE

COLD INFLATION

TIRE PRESSURE

FRONT

REAR

SOLO RIDING kPa kg/cm 2

150 1.50

psi

22

175 1.75

25

FUEL + OIL

ITEM

Fuel type

Fuel tank capacity

Engine oil type

Engine oil capacity

Front fork oil type

Front fork oil capacity (each leg)

Brake fluid type

DUAL RIDING kPa kg/cm 2

175 1.75

psi

25

200 2.00

29

SPECIFICATION

Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the research method.

Gasoline containing MTBE (Methyl Tertiary Butyl

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

Gasoline used should be graded 91 octane or higher. An unleaded gasoline is recommended.

Including reserve

12 L

(3.2/2.6 US/Imp gal)

13 L

(3.4/2.9 US/Imp gal)

Only reserve

3.0 L

(0.8/0.7 US/Imp gal)

Oil change

SAE 10W-40, API SF or SG

2 300 ml

(2.4/2.0 US/lmp qt)

Oil and filter change

2 400 ml

(2.5/2.1 US/lmp qt)

Engine overhaul

2 600 ml

(2.7/2.3 US/lmp qt)

Fork oil #10

565 ml

(19.1/19.9 US/lmp oz)

563 ml

(19.0/19.8 US/Imp oz)

DOT 4

NOTE

Low seat

NOTE

E-03, 28, 33

Others

E-33

Others

Low seat

DR650SEK9 (’09-MODELS) 12-1

DR650SE K9 (’ 09-MODELS)

CONTENTS

PAGE

SPECIFICATIONS....................................................................................... 12-2

NOTE:

* Difference between K9-MODEL and K8-MODEL specification is indicated as an asterisk mark (*).

* The service data is the same as the K8-MODEL.

11

12

12-2 DR650SEK9 (’09-MODEL)

SPECIFICATIONS

DIMENSIONS AND CURB MASS

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

2 255 mm (88.8 in)

2 235 mm (88.0 in).................... (Low seat)

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

865 mm (34.1 in)

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

1 195 mm (47.0 in)

1 155 mm (45.5 in).................... (Low seat)

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

1 490 mm (58.7 in)

1 475 mm (58.1 in).................... (Low seat)

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

265 mm (10.4 in)

225 mm (8.9 in)...................... (Low seat)

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

885 mm (34.8 in)

845 mm (33.0 in).................... (Low seat)

* Curb mass ........................................................................................

166 kg (366 lbs) ..................... E-03, 28, 33

165 kg (364 lbs) ..................... E-24

ENGINE

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

Four-stroke, air-cooled, OHC

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

1

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

100 mm (3.937 in)

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

82 mm (3.228 in)

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

644 cm 3 (39.3 cu. in)

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

9.5 : 1

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

MIKUNI BST40, single

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

Polyurethane foam element

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

Electric

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

Wet sump

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

1 500 ± 100 r/min

DRIVE TRAIN

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

Wet multi-plate type

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

5 speed constant mesh

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

1-down, 4-up

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

2.178 (61/28)

Gear ratios, Low...............................................................................

2.416 (29/12)

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

1.625 (26/16)

3rd ................................................................................

1.238 (26/21)

4th ................................................................................

1.000 (21/21)

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

0.826 (19/23)

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

2.800 (42/15)............................. E-03, 28, 33

2.733 (41/15)............................. E-24

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

DID 525V9, 110 links

CHASSIS

Front suspension .................................................................................

Telescopic, coil spring, oil damped

Rear suspension .................................................................................

Link type, coil spring, oil damped

Front fork stroke ..................................................................................

260 mm (10.2 in)

220 mm (8.7 in)......................... (Low seat)

Rear wheel travel ................................................................................

260 mm (10.2 in)

220 mm (8.7 in)......................... (Low seat)

Caster..................................................................................................

28° 30’

Trail......................................................................................................

111 mm (4.37 in)

Steering angle .....................................................................................

43° (right & left)

Turning radius......................................................................................

2.5 m (8.2 ft)

Front brake ..........................................................................................

Disc brake

Rear brake...........................................................................................

Disc brake

Front tire size.......................................................................................

90/90-21 M/C 54S, tube type

Rear tire size .......................................................................................

120/90-17 M/C 64S, tube type

ELECTRICAL

Ignition type .........................................................................................

Electronic ignition (CDI)

Ignition timing ......................................................................................

10° B.T.D.C. at 1 500 r/min

Spark plug ...........................................................................................

NGK CR10E or DENSO U31ESR-N

Battery.................................................................................................

12 V 28.8 kC (8 Ah)/10 HR

Generator ............................................................................................

Three-phase A.C. generator

Main fuse.............................................................................................

30 A

Fuse ....................................................................................................

10/10 A

Headlight .............................................................................................

12 V 60/55 W

Turn signal light ...................................................................................

12 V 21 W

Brake light/Taillight ..............................................................................

12 V 21/5 W

License plate light ...............................................................................

12 V 5 W

Speedometer light ...............................................................................

12 V 1.7 W

Neutral indicator light...........................................................................

12 V 2 W

High beam indicator light.....................................................................

12 V 2 W

Turn signal indicator light.....................................................................

12 V 2 W

DR650SEK9 (’09-MODEL) 12-3

CAPACITIES

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

12.0 L (3.2/2.6 US/Imp gal)..... E-33

13.0 L (3.4/2.9 US/Imp gal)..... Others reserve .............................................................................

3.0 L (0.8/0.7 US/Imp gal)

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

2 300 ml (2.4/2.0 US/Imp qt) with filter change ..............................................................

2 400 ml (2.5/2.1 US/Imp qt) overhaul............................................................................

2 600 ml (2.7/2.3 US/Imp qt)