Suzuki UF50 Service manual
Suzuki UF50, is a motorcycle with a powerful engine, advanced features, and a stylish design. Refer to the sections below to fully understand all the capabilities of your new device.
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UF50
9 9 5 0 0 - 1 0 4 9 1 - 0 1 E
FOREWORD
This manual contains an introductory description on the SUZUKI UF50/UF50Z and procedures for its inspection, service, and overhaul of its main components.
Other information considered as generally known is not included.
Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance.
Use this section as well as other sections as a guide for proper inspection and service.
This manual will help you know the motorcycle better so that you can assure your customers of fast and reliable service.
This manual has been prepared on the basis of the latest specifications at the time of publication. If modifications have been made since then, differences may exist between the content of this manual and the actual motorcycle.
Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual motorcycle exactly in detail.
This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcycles.
If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you.
GROUP INDEX
GENERAL INFORMATION
PERIODIC MAINTENANCE
ENGINE
FUEL AND LUBRICATION
SYSTEM
CHASSIS
ELECTRICAL SYSTEM
SERVICING INFORMATION
UF50K1 AND UF50ZK1 (’01-MODEL)
1
2
3
4
5
6
7
8
Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider and passenger.
© COPYRIGHT SUZUKI MOTOR ESPAÑA, S.A. 2000
HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE LOOKING
FOR:
1. The text of this manual is divided into sections.
2. The section titles are listed in the GROUP INDEX.
3. Holding the manual as shown at the right will allow you to find the first page of the section easily.
4. The contents are listed on the first page of each section to help you find the item and page you need.
COMPONENT PARTS AND WORK TO BE DONE
Under the name of each system or unit, is its exploded view. Work instructions and other service information such as the tightening torque, lubricating points and locking agent points, are provided.
Example: Front wheel
1 Front axle
2 Spacer
3 Brake disc
4 Bearing
5 Front wheel
6 Spacer
7 Speedometer gearbox
A Front axle nut
B Brake disc bolt
ITEM
A
B
N·m kgf-m
42 4.2
23 2.3
SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table.
SYMBOL DEFINITION
Torque control required.
Data beside it indicates specified torque.
SYMBOL DEFINITION
Apply or use brake fluid.
Indicates service data.
Measure in voltage range.
Apply oil. Use engine oil unless otherwise specified.
Apply SUZUKI SUPER GREASE “A”.
99000-25010
Apply SUZUKI MOLY PASTE.
99000-25140
Apply THREAD LOCK “1342”.
99000-32050
Apply THREAD LOCK SUPER “1322”.
99000-32110
Apply THREAD LOCK SUPER “1360”.
99000-32130
Measure in resistance range.
Measure in current range.
Measure in diode test range.
Measure in continuity test range.
Use special tool.
GENERAL INFORMATION
GENERAL INFORMATION
1-1
1
CONTENTS
WARNING/CAUTION/NOTE............................................................................ 1- 2
GENERAL PRECAUTIONS ............................................................................ 1- 2
SUZUKI UF50Y/UF50ZY (2000-MODEL) ....................................................... 1- 4
SERIAL NUMBER LOCATION ....................................................................... 1- 4
FUEL AND OIL RECOMMENDATIONS ......................................................... 1- 4
FUEL ............................................................................................................ 1- 4
ENGINE OIL ................................................................................................ 1- 4
FINAL GEAR OIL ........................................................................................ 1- 5
BRAKE FLUID ............................................................................................ 1- 5
BREAK-IN PROCEDURES ............................................................................. 1- 5
INFORMATION LABELS ................................................................................. 1- 6
SPECIFICATIONS ........................................................................................... 1- 7
1-2 GENERAL INFORMATION
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words.
Indicates a potential hazard that could result in death or injury.
Indicates a potential hazard that could result in motorcycle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARN-
INGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a particular service operation, ask a more experienced mechanic for advice.
GENERAL PRECAUTIONS
Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the motorcycle.
When two or more persons work together, pay attention to the safety of each other.
When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors.
When working with toxic or flammable materials, make sure that the area you work in is well ventilated and that you follow all of the manufacturer’s instructions.
Never use gasoline as a cleaning solvent.
To avoid getting burned, do not touch the engine, engine oil, and exhaust system until they have cooled.
After servicing the fuel, oil, exhaust or brake systems, check all of the lines, and fittings related to the system for leaks.
GENERAL INFORMATION 1-3
If parts replacement is necessary, replace the parts with SUZUKI Genuine Parts or their equivalent.
When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order.
Be sure to use special tools when instructed.
Make sure that all parts used in reassembly are clean. Lubricate them when specified.
Use the specified lubricants, bonds, or sealants.
wire.
service procedure requires the battery power.
When tightening cylinder head and crankcase nuts and bolts, tighten the larger sizes first.
Always tighten the nuts and bolts from the inside working out, diagonally and to the specified torque.
Whenever you remove oil seals, gaskets, packing, O-rings, self-locking nuts, locking washers, cotter pins, circlips, and other specified parts, 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 it is completely seated in its groove and securely fitted.
Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is smeared with them.
After reassembling, check parts for tightness and proper operation.
To protect the environment, do not unlawfully dispose of used motor oil, all other fluids, batteries, and tires.
To protect the earth’s natural resources, properly dispose of used motorcycles and parts.
1-4 GENERAL INFORMATION
SUZUKI UF50Y/UF50ZY (2000-MODEL)
RIGHT SIDE
* Difference between photographs and the actual motorcycles depends on the markets.
SERIAL NUMBER LOCATION
LEFT SIDE
The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the right side of the steering head pipe. The engine serial number 2 is located on the end of the crankcase. These numbers are required especially for registering the machine and ordering spare parts.
1
2
FUEL AND OIL RECOMMENDATIONS
Be sure to use the specified fuel and oils. Fuel and oil specifications are listed below.
FUEL
Use unleaded gasoline that is graded 91 octane or higher rated by the Research Method.
3 Fuel tank cap
ENGINE OIL
Use SUZUKI CCI SUPER OIL or an equivalent premium quality
2-stroke synthetic engine oil. Use only oils which are rated FC under the JASO classification.
4 Engine oil tank cap
3
4
GENERAL INFORMATION 1-5
FINAL GEAR OIL
Use a good quality SAE 10W-40 multigrade motor oil.
BRAKE FLUID
Specification and classification: DOT 4
This motorcycle uses a glycol-based brake fluid. Do not use or mix other types of brake fluid such as silicone-based and petroleum-based fluids for refilling the system, otherwise serious damage will result to the brake system.
Do not use any brake fluid taken from old, used, or unsealed containers.
Do not reuse brake fluid left over from the last servicing or which has been stored for a long period of time.
BREAK-IN PROCEDURES
During manufacturing only the best possible materials are used and all machined parts are finished to a very high standard. It is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. Refer to the following break-in engine speed recommendations.
Keep to these break-in throttle positions during the break-in period.
Break-in throttle position
Initial 800 km: Less than 1/2 throttle
Up to 1 600 km: Less than 3/4 throttle
Upon reaching an odometer reading of 1 600 km you can subject the motorcycle to full throttle operation, for short periods of time.
1-6 GENERAL INFORMATION
INFORMATION LABELS
General warning label
Loading cap label
Tire information label
Engine starting label
Battery caution label
GENERAL INFORMATION 1-7
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ................................................... 1 840 mm
Overall width .................................................... 650 mm
Overall height ................................................... 1 095 mm
Wheelbase ....................................................... 1 255 mm
Ground clearance ............................................
135 mm
Seat height ....................................................... 795 mm
Dry mass ..........................................................
83 kg
ENGINE
Type .................................................................. Two-stroke, forced air-cooled
Intake system ................................................... Reed valve
Number of cylinders ......................................... 1
Bore ................................................................. 41.0 mm
Stroke ............................................................... 37.4 mm
Piston displacement ........................................ 49 cm 3
Corrected compression ratio ........................... 7.2:1
Carburetor ........................................................ KEIHIN PWS14
Air cleaner ........................................................ Polyurethane foam element
Starter system .................................................. Electric and kick
Lubrication system ........................................... SUZUKI “CCI”
TRANSMISSION
Clutch ............................................................... Dry shoe, automatic, centrifugal type
Gearshifting ..................................................... Automatic, variable ratio
Gear ratios ....................................................... Variable reduction ratio... (2.975 – 1.033)
Final reduction ratio ......................................... 13.812 (51/15)
× (65/16)
Drive system .................................................... V-belt drive
1-8 GENERAL INFORMATION
CHASSIS
Front suspension ............................................. Inverted telescopic, coil spring
Rear suspension .............................................. Swingarm type, coil spring, oil damped
Steering angle ................................................. 45° (right & left)
Caster .............................................................. 25°30’
Trail ................................................................... 82 mm
Turning radius .................................................. 1.9 m
Front brake ....................................................... Disc brake
Rear brake ....................................................... Internal expanding
Front tire size ................................................... 120/70-12 51L
Rear tire size .................................................... 130/70-12 56L
ELECTRICAL
Ignition type ..................................................... Electronic ignition (CDI)
Spark plug ........................................................ NGK: BPR7HS or DENSO: W22FPR
Battery ............................................................. 12 V 14.4 kC (4 Ah)/10 HR
Generator ......................................................... Generator
Fuse ................................................................. 10 A
Headlight .......................................................... 12 V 35/35 W
Brake light/taillight ............................................ 12 V 21/5 W
Turn signal light ................................................ 12 V 10 W
CAPACITIES
Fuel tank .......................................................... 6.0 L
Engine oil tank ................................................. 1.2 L
Final gear oil .................................................... 130 ml
NOTE:
These specifications are subject to change without notice.
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
2-1
CONTENTS
PERIODIC MAINTENANCE SCHEDULE ....................................................... 2- 2
PERIODIC MAINTENANCE CHART .......................................................... 2- 2
MAINTENANCE AND TUNE-UP PROCEDURE ............................................. 2- 3
BATTERY..................................................................................................... 2- 3
AIR CLEANER ............................................................................................ 2- 4
CYLINDER HEAD AND CYLINDER ........................................................... 2- 5
SPARK PLUG .............................................................................................. 2- 5
CARBURETOR ........................................................................................... 2- 7
FUEL LINE .................................................................................................. 2- 7
FINAL GEAR OIL ........................................................................................ 2- 8
BRAKES ...................................................................................................... 2- 8
BRAKE HOSE ............................................................................................. 2- 9
BRAKE FLUID ............................................................................................ 2- 9
STEERING .................................................................................................. 2-11
FRONT FORK ............................................................................................. 2-11
REAR SUSPENSION .................................................................................. 2-11
TIRES .......................................................................................................... 2-12
CYLINDER HEAD NUTS AND EXHAUST PIPE NUT AND BOLT ............ 2-13
CHASSIS NUTS AND BOLTS .................................................................... 2-13
GENERAL LUBRICATION .......................................................................... 2-15
AUTOMATIC CLUTCH INSPECTION ............................................................. 2-16
INITIAL ENGAGEMENT ............................................................................. 2-16
CLUTCH LOCK-UP ..................................................................................... 2-17
2
2-2 PERIODIC MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE
The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometers and months, and are dependent on whichever comes first.
NOTE:
More frequent servicing may be performed on motorcycles that are used under severe conditions.
PERIODIC MAINTENANCE CHART
Interval
Item
Battery
Air cleaner
Cylinder head and cylinder
Spark plug
Carburetor
Fuel line km months
Final gear oil
Brakes
Brake hose
Brake fluid
Steering
Front fork
Rear suspension
Tires
Cylinder head nuts and exhaust pipe nut and bolt
Chassis nuts and bolts
Initial 1 000
2
–
–
I
I
–
–
I
I
–
–
I
–
–
I
T
T
Every 3 000
6
I
C
I
I
C
C
Replace every four years.
–
I
I
Replace every four years.
I
Replace every two years.
I
I
T
–
–
T
Every 6 000
12
I
C
I
I
C
R
I
I
I
I
I
I
I
I
T
T
NOTE: I : Inspect and clean, adjust, lubricate, or replace as necessary.
C : Clean
R : Replace
T : Tighten
PERIODIC MAINTENANCE 2-3
MAINTENANCE AND TUNE-UP
PROCEDURE
This section describes the servicing procedures for each item mentioned in the periodic maintenance chart on the previous page.
BATTERY
Inspect every 3 000 km (6 months).
Remove the battery holder cover. ( 6-30)
First, disconnect the - battery lead wire, and then disconnect the + battery lead wire.
Check the electrolyte level. It should be within the UPPER LEVEL and LOWER LEVEL lines. If the electrolyte is below the LOWER
LEVEL line, add distilled water to the UPPER LEVEL line. Use a hydrometer 1 to measure the specific gravity of the electrolyte.
09900-28403: Hydrometer
A specific gravity reading of 1.22 (at 20°C) or less means that the battery needs to be recharged. Remove the battery from the motorcycle and charge it with a battery charger.
Standard specific gravity: 1.280 at 20°C
When removing the battery from the motorcycle, be
sure to disconnect the - battery lead wire first.
Never charge a battery while it is still in the motorcycle, as damage may result to the battery or regulator/rectifier.
Be careful not to bend, obstruct, or change the routing of the battery breather hose. Make sure that the battery breather hose is attached to the battery vent and that its opposite end is always unobstructed.
When installing the battery lead wires, install the +
battery lead wire first.
a Battery b Battery holder c Battery breather hose d Slit of breather hose
Forward
UPPER LEVEL
LOWER LEVEL
a c b d
2-4 PERIODIC MAINTENANCE
AIR CLEANER
Clean every 3 000 km (6 months).
If the air cleaner is clogged with dust, intake resistance will be increased, with a resultant decrease in engine output and an increase in fuel consumption. Check and clean the air cleaner elements in the following manner.
Remove the air cleaner case cover 1.
Remove air cleaner elements 2 and 3.
Fill a washing pan of a proper size with a nonflammable cleaning solvent. Immerse the air cleaner elements in the cleaning solvent and wash them.
Press the air cleaner element between the palms of both hands to remove the excess solvent: do not twist or wring the elements or they will develop tears.
Immerse the elements in motor oil, and squeeze out the excess oil. The elements should be wet but not dripping.
Properly install the air cleaner elements into the air cleaner case.
A Nonflammable cleaning solvent
B Motor oil SAE #30 or SAE 10W-40
Inspect the air cleaner element for tears. A torn element must be replaced.
When installing the air cleaner elements, install the fine mesh air cleaner element first, and then install the large mesh air cleaner element.
Be sure to position the air cleaner element snugly and correctly, so that no incoming air will bypass it.
Remember, rapid wear of the piston rings and cylinder bore is often caused by a defective or poorly fitted air cleaner element.
1
2
3
CYLINDER HEAD AND CYLINDER
(
Remove carbon every 3 000 km (6 months).
3-13)
SPARK PLUG
Clean every 3 000 km (6 months).
Replace every 6 000 km (12 months).
Remove the left side leg shield. ( 5-3)
Disconnect the spark plug cap and remove the spark plug.
Standard
NGK DENSO
BPR7HS W22FPR
CARBON DEPOSIT
Check for carbon deposits on the spark plug. If any carbon is deposited on the spark plug, remove it using a spark plug cleaner machine or carefully use a tool with a pointed end.
PERIODIC MAINTENANCE 2-5
2-6 PERIODIC MAINTENANCE
SPARK PLUG GAP
Measure the spark plug gap using a thickness gauge. If the spark plug gap is out of specification, adjust the gap.
Spark plug gap
Standard: 0.6 – 0.7 mm
09900-20804: Thickness gauge
ELECTRODES
Check the condition of the electrodes.
If the electrode is extremely worn or burnt, replace the spark plug with a new one.
Also, replace the spark plug if it has a broken insulator, damaged threads, etc.
Check the tread size and reach when replacing the spark plug. If the reach is too short, carbon will be deposited on the screw portion of the spark plug hole and engine damage may result.
SPARK PLUG INSTALLATION
To avoid damaging the cylinder head threads; first, finger tighten the spark plug, and then tighten it to the specified torque using the spark plug wrench.
Insert the spark plug and finger tighten it to the cylinder head and then tighten it to the specified torque.
Spark plug: 28 N·m (2.8 kgf-m)
0.6 – 0.7 mm
CARBURETOR
Inspect Initially at 1 000 km (2 months) and every
3 000 km (6 months) thereafter.
ENGINE IDLE SPEED
Adjust the throttle cable play.
Remove the left side leg shield. (
Warm up the engine.
5-3)
NOTE:
Make this adjustment when the engine is hot.
Connect the multi circuit tester to the high-tension cord.
Start the engine, and then turn the throttle stop screw 1 to set the engine idle speed as shown below.
Engine idle speed: 1 900 ± 200 r/min
09900-25008: Multi circuit tester set
THROTTLE CABLE PLAY
Throttle cable play A should be 2 – 4 mm as measured at the throttle grip when turning the throttle grip lightly. If the throttle cable play A is incorrect, adjust it as follows:
Loosen the locknut 1 and turn the adjuster 2 in or out until the specified play is obtained.
Tighten the locknut 1 while holding the adjuster 2.
Throttle cable play A: 2 – 4 mm
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.
PERIODIC MAINTENANCE 2-7
1
2
1
FUEL LINE
Inspect initially at 1 000 km (2 months) and every
3 000 km (6 months) thereafter.
Replace every four years.
2-8 PERIODIC MAINTENANCE
FINAL GEAR OIL
Inspect initially at 1 000 km (2 months) and every
6 000 km (12 months) thereafter.
Remove the final gear oil level bolt 1 and inspect the oil level.
If the oil level is below the brim of the final gear oil level hole, add oil until it runs out from the level hole.
Final gear oil viscosity and classification: SAE 10W-40
Tighten the final gear oil level bolt 1 to the specified torque.
Final gear oil level bolt: 12 N·m (1.2 kgf-m)
1
BRAKES
Inspect initially at 1 000 km (2 months) and every
3 000 km (6 months) thereafter.
REAR BRAKE LEVER PLAY
Turn the adjusting nut 1 until the rear brake lever play A is within specification.
Rear brake lever play A: 15 – 25 mm
REAR BRAKE SHOE WEAR
This motorcycle is equipped with a brake lining wear limit indicator 1 on the brake cam lever.
To check brake lining wear, perform the following steps.
Make sure that the rear brake lever play is properly adjusted.
Squeeze the rear brake lever. Make sure that the indicator 1 is within the range A embossed on the crankcase.
If the indicator goes beyond the range, the brake shoe assembly should be replaced with a new set of shoes. (
5-30)
(
FRONT BRAKE PADS
5-11)
1
1
A
A
BRAKE HOSE
Inspect every 3 000 km (6 months).
Replace every four years.
Check the brake hose for leakage, cracks, wear, and damages.
If any damages are found, replace the brake hose with a new one.
BRAKE FLUID
Inspect every 3 000 km (6 months).
Replace fluid every two years.
FRONT BRAKE FLUID LEVEL
Keep the motorcycle upright and place the handlebars straight.
Check the brake fluid level by observing the lower limit line on the brake fluid reservoir.
When the brake fluid level is below the lower limit line, replenish with a brake fluid that meets the following specification.
NOTE:
If the brake fluid level is difficult to check, remove the master cylinder reservoir cap to check the brake fluid level.
Specification and classification: DOT 4
The brake system is filled with an glycol-based brake fluid, which is classified DOT 4. Do not use or mix other types of brake fluid, such as silicone-based and petroleum-based brake fluids when refilling the brake system, otherwise serious damage to the brake system will result.
Do not use any brake fluid taken from old, used, or unsealed containers.
Do not reuse brake fluid left over from the last servicing or which has been stored for a long period of time.
When storing brake fluid, be sure to seal the container completely and keep it out of the reach of children.
When replenishing brake fluid, be sure not to get any dust or other foreign materials in the fluid.
Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces. Check the brake hoses and hose joints for cracks and oil leakage before riding.
PERIODIC MAINTENANCE 2-9
2-10 PERIODIC MAINTENANCE
AIR BLEEDING THE BRAKE FLUID CIRCUIT
Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder, thus interferes with the full braking performance of the brake caliper. The presence of air is indicated by “sponginess” of the brake lever and also by lack of braking force. Considering the danger to which such trapped air exposes the machine and rider, it is essential that, after remounting the brake and restoring the brake system to the normal condition, the brake fluid circuit be purged of air in the following manner:
Fill the master cylinder reservoir to the upper end of the inspection window. Replace the reservoir cap to prevent dirt from entering.
Attach a hose to the caliper bleeder valve, and insert the free end of the hose into a receptacle.
Bleed air from the 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:
While bleeding the brake system, replenish the brake fluid in the reservoir as necessary. Make sure that there is always some fluid visible in the reservoir.
Close the bleeder valve, and disconnect the hose. Fill the reservoir with brake fluid to the top of the inspection window.
Air bleeder valve: 7.5 N·m (0.75 kgf-m)
Handle the brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials, etc.
STEERING
Inspect Initially at 1 000 km (2 months) and every
3 000 km (6 months) thereafter.
The steering should be adjusted properly for smooth turning of the handlebar and safe operation. Overtight steering prevents smooth turning of the handlebar and too loose steering will cause poor stability. Check that there is no play in the front fork. Support the motorcycle so that the front wheel is off the ground. With the wheel facing straight ahead, grasp the lower fork tubes near
( the axle and pull forward. If play is found, adjust the steering.
5-28 and 5-29)
PERIODIC MAINTENANCE 2-11
FRONT FORK
Inspect every 6 000 km (12 months).
Inspect the front fork for scoring or scratches on the outer surface of the inner tubes. If any damages are found, replace the inner tubes with new ones. ( 5-18 and 5-19)
REAR SUSPENSION
Inspect every 6 000 km (12 months).
Inspect the rear shock absorber for oil leakage and the bushings for wear and damage. If oil leakage or any damages are found, replace the rear shock absorber with a new one.
2-12 PERIODIC MAINTENANCE
TIRES
Inspect initially at 1 000 km (2 months) and every
3 000 km (6 months) thereafter.
TIRE TREAD CONDITION
Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of the tire tread reaches the following specification.
Tire tread depth (front and rear)
Service Limit: 1.6 mm
09900-20805: Tire depth gauge
TIRE PRESSURE
If the tire pressure is too high or too low, steering will be adversely affected and tire wear will increase. Therefore, maintain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows.
Cold inflation tire pressure
Solo riding
Front: 125 kPa (1.25 kgf/cm
2
)
Rear: 175 kPa (1.75 kgf/cm
2
)
Dual riding (except for UF50Z)
Front: 125 kPa (1.25 kgf/cm
2
)
Rear: 230 kPa (2.30 kgf/cm
2
)
The standard tire fitted on this motorcycle is 120/70-12
51L for the front and 130/70-12 56L for the rear. The use of tires other than those specified may cause instability. It is highly recommended to use the specified tires.
PERIODIC MAINTENANCE 2-13
CYLINDER HEAD NUTS AND EXHAUST
PIPE NUT AND BOLT
Tighten initially at 1 000 km (2 months) and every
3 000 km (6 months) thereafter.
Cylinder head nuts, when they are not tightened to the specified torque, may result in leakage of the compressed mixture and reduce output. Tighten the cylinder head nuts as follows.
Disconnect the spark plug cap and remove the spark plug.
( 2-5)
Remove the frame cover. ( 5-4 and 5-5)
Remove the cylinder/cylinder head cover 1.
Disconnect the spark plug cap.
Tighten the cylinder head nuts 2 and exhaust pipe nut 3 and bolt 4 to the specified torque.
Cylinder head nut: 10 N·m (1.0 kgf-m)
Exhaust pipe nut and bolt: 10 N·m (1.0 kgf-m)
2
CHASSIS NUTS AND BOLTS
Tighten initially 1 000 km (2 months) and every
3 000 km (6 months) thereafter.
Check that all chassis nuts and bolts are tightened to their specified torque.
Item
1 Front axle nut
2 Steering stem locknut
3 Handlebar set bolt
4 Handlebar clamp nut
5 Front brake caliper mounting bolt
6 Front brake hose union bolt
7 Front brake caliper air bleeder valve
8 Front brake disc mounting bolt
9 Front brake master cylinder clamp bolt
0 Rear axle nut
A Rear shock absorber upper mounting bolt
B Rear shock absorber lower mounting nut
C Rear brake cam lever nut
7.5
23
10
120
29
35
10
N·m
42
30
25
50
26
23
1
2
3
4
0.75
2.3
1.0
12.0
2.9
3.5
1.0
kgf-m
4.2
3.0
2.5
5.0
2.6
2.3
2-14 PERIODIC MAINTENANCE
1
5
8
7
6
0
C
6
4
3
2
9
A
B
PERIODIC MAINTENANCE 2-15
GENERAL LUBRICATION
Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.
Major lubrication points are indicated below.
1
3
2
1 Rear brake lever holder
2 Center stand pivot and spring hook
4
3 Front brake lever holder
4 Speedometer cable
NOTE:
Before lubricating each part, remove any rust and wipe off any grease, oil, dirt, or grime.
Lubricate exposed parts which are subject to rust, with a rust preventative spray, especially whenever the motorcycle has been operated under wet or rainy conditions.
2-16 PERIODIC MAINTENANCE
AUTOMATIC CLUTCH INSPECTION
The UF50/UF50Z is equipped with a centrifugal type automatic clutch and a variable ratio belt drive transmission.
To insure proper performance and longevity of the clutch assembly it is essential that the clutch assembly engages smoothly and gradually. Two inspection checks must be performed to thoroughly check the operation of the drive train. Follow the procedures listed.
NOTE:
Warm up the engine.
INITIAL ENGAGEMENT
Remove the trunk. ( 5-4)
Connect the multi circuit tester to the high-tension cord.
Start the engine.
While seated on the machine, slowly increase the engine speed and record the speed when the machine begins to move forward.
09900-25008: Multi circuit tester
Engagement speed: 4 100 – 4 500 r/min
If the engagement speed does not coincide with the standard range, refer to the following section to inspection the respective items for any abnormalities.
CLUTCH SHOE/MOVABLE
DRIVEN FACE ...........................................
3-18 to 3-22
CLUTCH LOCK-UP
Perform this inspection to determine if the clutch is engaging fully and not slipping.
Remove the trunk. ( 5-4)
Connect the multi circuit tester to the high-tension cord.
Start the engine.
Apply the rear brake as firm as possible.
Fully open the throttle for a brief period and note the maximum engine speed sustained during the test cycle.
09900-25008: Multi circuit tester
Lock-up speed: 5 600 – 6 200 r/min
Do not apply full power for more than 10 seconds or damage to the clutch assembly or engine may occur.
If the lock-up speed does not coincide with the standard range, refer to the following section to inspect the respective items for any abnormalities.
CLUTCH SHOE/MOVABLE
DRIVEN FACE ...........................................
3-18 to 3-22
PERIODIC MAINTENANCE 2-17
ENGINE 3-1
ENGINE
CONTENTS
ENGINE COMPONENTS REMOVABLE WITH THE
ENGINE IN PLACE .......................................................................................... 3- 2
ENGINE REMOVAL AND REMOUNTING ...................................................... 3- 3
ENGINE REMOVAL .................................................................................... 3- 3
ENGINE REMOUNTING ............................................................................. 3- 5
ENGINE DISASSEMBLY................................................................................. 3- 6
ENGINE COMPONENTS INSPECTION AND SERVICE ............................... 3-13
CYLINDER HEAD DISTORTION ................................................................ 3-13
CYLINDER................................................................................................... 3-13
PISTON ........................................................................................................ 3-14
CRANKSHAFT AND CONROD .................................................................. 3-16
REED VALVE ............................................................................................... 3-17
CLUTCH SHOE/MOVABLE DRIVEN FACE ............................................... 3-18
MOVABLE DRIVE FACE ............................................................................. 3-23
KICK STARTER........................................................................................... 3-25
BEARINGS .................................................................................................. 3-26
OIL SEALS .................................................................................................. 3-28
ENGINE MOUNTING BUSHINGS .............................................................. 3-31
ENGINE REASSEMBLY .................................................................................. 3-32
CRANKSHAFT ............................................................................................ 3-32
CRANKCASE .............................................................................................. 3-32
REAR AXLE SHAFT AND TRANSMISSION .............................................. 3-34
GENERATOR .............................................................................................. 3-36
STARTER PINION AND STARTER GEAR ................................................. 3-37
DRIVE BELT ................................................................................................ 3-38
PISTON ........................................................................................................ 3-39
CYLINDER................................................................................................... 3-40
CYLINDER HEAD ....................................................................................... 3-40
OIL PUMP GEAR ........................................................................................ 3-40
INTAKE PIPE ............................................................................................... 3-40
EXHAUST PIPE/MUFFLER ........................................................................ 3-40
3
3-2 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 reinstallation instructions.
ENGINE LEFT SIDE
PARTS
Air cleaner
Kick starter lever
Clutch cover
Kick starter
Fixed drive face
Movable drive face
Clutch housing
Clutch shoe assembly
Drive belt
Starter driven gear
Starter pinion gear
ENGINE RIGHT SIDE
PARTS
Exhaust pipe/muffler assembly
Cooling fan
Starter motor
Generator rotor
Stator coil
Pickup coil
Gearbox cover
Final driven gear
REMOVAL
3-6
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-10
REMOVAL
3-6
3-7
3-8
3-10
3-10
3-10
3-11
3-11
INSTALLATION
–
3-39
3-39
3-38
–
3-38
3-38
–
3-38
3-37
3-37
INSTALLATION
3-40
–
–
3-37
3-36
3-36
3-35
3-34
ENGINE CENTER
Oil pump
Oil pump gear
Intake pipe
Reed valve
Cylinder head
Cylinder
Piston
PARTS REMOVAL
3-6
3-7
3-7
3-7
3-8
3-8
3-8
INSTALLATION
–
3-40
3-40
–
3-40
3-40
3-39
ENGINE 3-3
ENGINE REMOVAL AND
REMOUNTING
ENGINE REMOVAL
Before taking the engine out of the frame, wash the engine with a steam cleaner. Engine removal is sequentially explained in the following steps.
Remove the side leg shields and frame covers. ( 5-3 to
5-5)
Disconnect the - battery lead wire. ( 6-30)
Disconnect the fuel hose 1, vacuum hose 2, oil hose 3, and carburetor heater lead wire 4.
Remove the carburetor top cap 5 with the throttle cable and throttle valve.
2
3
4
5
1
Disconnect the spark plug cap.
Disconnect the engine ground wire.
Disconnect the thermoelement coupler 6, starter motor coupler 7, and generator coupler 8.
6
7
8
3-4 ENGINE
Remove the rear brake cable holders 1 and adjusting nut 2.
1
1
1
2
Disconnect the air cleaner intake boot.
Remove the rear shock absorber lower mounting bolt.
Remove the engine mounting nut, shaft, and engine.
ENGINE REMOUNTING
Remount the engine in the reverse order of removal. Pay attention to the following points:
Install the crankcase bracket 1 to the frame and insert the crankcase bracket mounting shaft.
Push down on the rear part of the crankcase bracket and have the damper 2 touch the stopper 3. While holding the damper, tighten the engine mounting bracket nut 4 to the specified torque.
Engine mounting bracket nut: 65 N·m (6.5 kgf-m)
Install the engine and tighten the engine mounting nut 5 to the specified torque.
Engine mounting nut: 60 N·m (6.0 kgf-m)
NOTE:
When tightening the engine mounting nut, make sure that the front wheel is elevated.
Tighten the rear shock absorber lower mounting nut 6 to the specified torque.
Rear shock absorber nut: 35 N·m (3.5 kgf-m)
Place 65 kg on the seat, after installing the engine.
Check that clearances A and B are equal. If clearances A and B are not equal, repeat the engine installation procedures.
After installing the engine, properly route the wire harness, cables, and hoses. Refer to the wire and cable routing sections. ( 7-10 to 7-16)
Refer to the following sections to adjust the respective items to specification.
THROTTLE CABLE PLAY .......................................
ENGINE IDLE SPEED .............................................
REAR BRAKE CABLE ADJUSTMENT .................
OIL PUMP AIR BLEEDING ..................................
2-7
2-7
2-8
4-13
ENGINE 3-5
3-6 ENGINE
ENGINE DISASSEMBLY
Remove the air cleaner.
Remove the exhaust pipe/muffler assembly.
Disconnect the oil hoses and remove the oil pump.
Remove the oil pump gear 1, intake pipe and carburetor.
A: Twist-off bolt
Remove the reed valve and gaskets.
Remove the cylinder/cylinder head cover 2 and cooling fan cover 3.
2
Remove the cooling fan.
Remove the cooling fan case.
ENGINE 3-7
1
A
3
3-8 ENGINE
Remove the rear fender.
Loosen the cylinder head nuts diagonally, as shown, and then remove them.
Remove the cylinder head and gasket.
Remove the cylinder and gasket.
Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into the crankcase. Then, remove the piston pin circlip with long-nose pliers.
Remove the piston pin and piston.
Remove the starter motor.
Remove the kick starter lever 1, clutch cover 2, gaskets, and dowel pins.
2
ENGINE 3-9
1
Hold the generator rotor using the special tool and then remove the kick starter nut.
09930-40113: Rotor holder
Remove the kick starter 3, fixed drive face 4, movable drive face 5, spacers, and washers.
4
3
5
Hold the clutch housing using the special tool and then remove the clutch housing nut.
09930-40113: Rotor holder
Remove the clutch housing, clutch shoe assembly, and drive belt.
Remove the starter driven gear.
3-10 ENGINE
Remove the starter pinion gear cap 1, starter pinion gear assembly 2, and dowel pins.
Drain the final gear oil.
Hold the generator rotor using the special tool and then remove the generator rotor nut.
09930-40113: Rotor holder
Remove the generator rotor using the special tool.
09920-13120: Crankcase separating tool
Remove the stator coil 3, pickup coil 4, and key 5.
3
5
4
ENGINE 3-11
Remove the rear wheel.
Remove the brake shoes.
Remove the brake cam lever 1, return spring 2, brake lining wear limit indicator 3, and brake camshaft 4.
3
1
2
4
Remove the gearbox cover.
Remove the final driven gear with the rear axle shaft 5, idle shaft/gear 6, and dowel pins 7.
7
5
6
7
3-12 ENGINE
Remove the driveshaft using the special tool.
09920-13120: Crankcase separating tool
Remove the center stand spring 1.
Remove the cotter pin 2 and center stand shaft 3.
Remove the center stand 4.
Remove the crankcase bolts.
Separate the left and right crankcases using the special tool.
09920-13120: Crankcase separating tool
Remove the gaskets and dowel pins.
Replace the removed gaskets with new ones.
Remove the crankshaft using the special tool.
09920-13120: Crankcase separating tool
ENGINE 3-13
ENGINE COMPONENTS INSPECTION
AND SERVICE
CYLINDER HEAD DISTORTION
Decarbonize the combustion chamber.
Check the gasket surface of the cylinder head for distortion. Use a straightedge and thickness gauge. Take clearance readings at several places. If readings exceed the service limit, replace or flatten the cylinder head.
09900-20803: Thickness gauge
Cylinder head distortion
Service Limit: 0.05 mm
Place a sheet of emery paper (about #400 grit) on a surface plate. Use a figure-eight motion when grinding the cylinder head surface.
The gasket surface must be smooth and perfectly flat, for a tight fit. A leaky joint can cause reduced power and increased fuel consumption.
CYLINDER
Remove carbon from the exhaust port and the upper part of the cylinder. Take care not to damage the surface of the cylinder wall.
CYLINDER BORE
Measure the cylinder bore with the cylinder gauge at 20 mm from the top of the cylinder.
If the measurement exceeds the service limit, rebore the cylinder and replace the piston with an oversized piston or replace the cylinder with a new one. Oversized pistons are available in two sizes: 0.5 mm and 1.0 mm.
09900-20508: Cylinder gauge set
Cylinder bore
Service Limit: 41.075 mm
Chamfer the port edges after reboring. Use a scraper and take care not to nick the surface of the walls. Use emery paper (about
#400 grit) to smooth the chamfered edges.
NOTE:
Shallow grooves or minor scuffs can be removed by using emery paper (about #400 grit). If the flaws are deep grooves or cannot be removed with the emery paper, the cylinder must be rebored to the next oversize.
1.0 – 1.5 mm
1.0 – 1.5 mm
0.3 – 0.5 mm
3-14 ENGINE
PISTON
PISTON DIAMETER
Measure the piston diameter using a micrometer at 15 mm from the skirt end.
If the piston diameter is less than the service limit, replace the piston with a new one.
09900-20202: Micrometer (25 – 50 mm)
Piston diameter
Service Limit: 40.885 mm
PISTON-TO-CYLINDER CLEARANCE
Subtract the piston diameter from the cylinder bore diameter. If the piston-to-cylinder clearance exceeds the service limit, rebore the cylinder and use an oversized piston or replace both the cylinder and the piston with new ones.
Piston-to-cylinder clearance
Service Limit: 0.120 mm
CARBON REMOVAL
Remove carbon from the crown of the piston and piston ring grooves. After cleaning the piston ring grooves, install the piston rings and rotate them in their respective grooves to be sure that they move smoothly.
Carbon in the piston ring groove can cause the piston ring to get stuck, reducing engine power output.
If any scuffing is found, replace the piston with a new one.
Shallow grooves or minor scuffs can be removed by using emery paper (about #400 grit) as shown.
PISTON PIN AND PIN BORE
Measure the piston pin bore inside diameter using the dial calipers and the piston pin outside diameter using the micrometer. If either is out of specification or the difference between the measurements is more than their limits, replace the piston and piston pin with new ones.
09900-20605: Dial calipers
09900-20205: Micrometer (0 – 25 mm)
Piston pin bore I.D.
Service Limit: 10.030 mm
Piston pin O.D.
Service Limit: 9.980 mm
PISTON RING FREE END GAP AND PISTON RING END GAP
Measure the piston ring free end gap using vernier calipers. Then, fit the piston ring squarely into the cylinder and measure the piston ring end gap using a thickness gauge.
If any of the measurements exceed the service limit, replace the piston ring with a new one.
09900-20101: Vernier calipers
Piston ring free end gap
Service Limit:
1st: 3.2 mm ... R
2nd: 3.4 mm ... R
09900-20803: Thickness gauge
Piston ring end gap
Service Limit: 0.80 mm
Measure the piston-ring-to-groove clearance using the thickness gauge.
If any of the clearances are out of specification, clean the groove of the piston and piston rings.
09900-20803: Thickness gauge
Piston-ring-to-groove clearance
Standard:
1st: 0.03 – 0.07 mm
2nd: 0.02 – 0.06 mm
ENGINE 3-15
3-16 ENGINE
CRANKSHAFT AND CONROD
1 Oil seal (R)
2 Bearing (R)
3 Crankshaft (R)
4 Crank pin
5 Crank pin bearing
6 Conrod
7 Crankshaft (L)
8 Spacer
9 Piston pin bearing
0 Bearing (L)
A Oil seal (L)
B Oil seal
CRANKSHAFT RUNOUT
Support the crankshaft using V-blocks as shown. Position the dial gauge, as shown, and rotate the crankshaft slowly to read the runout. If the runout exceeds the service limit, correct the runout or replace the crankshaft assembly with a new one.
09900-20701: Magnetic stand
09900-20606: Dial gauge (1/100 mm)
09900-21304: V-block set (100 mm)
Crankshaft runout
Service Limit: 0.05 mm
CONROD DEFLECTION
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 big end of the conrod.
09900-20701: Magnetic stand
09900-20606: Dial gauge (1/100 mm)
09900-21304: V-block set (100 mm)
Conrod deflection
Service Limit: 3.0 mm
If the service limit is exceeded, replace the crankshaft assembly or bring the deflection into specification by replacing the worn parts (e.g., conrod, big end bearing and crank pin).
CONROD SMALL END I.D.
Measure the conrod small end inside diameter using the dial calipers. If the conrod small end inside diameter exceeds the service limit, replace the conrod with a new one.
Conrod small end I.D.
Service Limit: 14.040 mm
09900-20605: Dial calipers
REASSEMBLY
When rebuilding the crankshaft, the width between the webs should be within the standard range.
Crank web to web width
Standard: 36.0 ± 0.05 mm
REED VALVE
Inspect the reed valve for wear or damage. If any damages are found, replace the reed valve with a new one.
ENGINE 3-17
3-18 ENGINE
CLUTCH SHOE/MOVABLE DRIVEN FACE
1 Fixed driven face
2 Bearing
3 Circlip
4 Needle roller bearing
5 Movable driven face
6 Oil seal
7 Pin
8 O-ring
9 Movable driven face spring guide
0 Oil seal
A Spring
B Clutch shoe assembly
C Clutch housing
D Washer
A Clutch shoe nut
B Clutch housing nut
DISASSEMBLY
If the engine speed does not coincide with the specified engine speed range, disassemble the clutch shoe/movable driven face as follows.
Hold the clutch shoe assembly using the special tools and then loosen the clutch shoe nut.
09930-40113: Rotor holder
09930-40131: Rotor holder attachment
Remove the clutch shoe nut 1 while holding down the clutch shoe assembly, as shown.
Gradually ease apart the clutch shoe assembly (to counter the clutch spring force). Quickly releasing the clutch shoe assembly may cause the parts to fly apart.
ITEM
A
B
N·m kgf-m
50 5.0
50 5.0
Remove the clutch shoe assembly 1 and driven face spring 2.
Use a thin-blade screwdriver to pry up the movable driven face spring guide.
Remove the pins 3, movable driven face 4, and fixed driven face 5.
Remove the bearing using the special tools.
09923-73210: Bearing remover
09930-30102: Sliding hammer
Replace the removed bearing with a new one.
Remove the circlip.
ENGINE 3-19
3-20 ENGINE
Remove the bearing using the special tool.
09941-50111: Bearing remover
Replace the removed bearing with a new one.
Remove the oil seals 1 and O-rings 2.
Replace the removed oil seals and O-rings with new ones.
CLUTCH SHOE
Inspect the clutch shoe for chips, cracks, uneven wear and burning. Check the thickness of the shoe using vernier calipers. If any damages are found or if the thickness is less than the service limit, replace the clutch shoe with a new one.
09900-20101: Vernier calipers
Clutch shoe thickness
Service Limit: 2.0 mm
Inspect the clutch spring for stretched or broken coils. If any damages are found, replace the clutch spring with a new one.
Replace the clutch shoe and clutch spring as a set.
Inspect the clutch housing surface for scrolling, cracks, or uneven wear and measure the inside diameter of the clutch housing with inside calipers. Measure the diameter at several points to check for out-of-round and wear. If any damages are found or if the inside diameter exceeds the service limit, replace the clutch housing with a new one.
Clutch housing I.D.
Service Limit: 110.50 mm
DRIVEN FACE SPRING
Measure the free length of the driven face spring. If the length is shorter than the service limit, replace the spring with a new one.
Driven face spring length
Service Limit: 104.5 mm
DRIVEN FACE PINS AND OIL SEALS
Rotate the driven faces and make sure that they turn smoothly.
If they stick or do not turn smoothly, inspect the lip of each oil seal, and the sliding surface and sliding pins for wear or damage. If any damages are found, replace the driven face with a new one.
DRIVEN FACE
Inspect the drive belt contacting surface of both driven faces for any scratches, wear or damage. If any damages are found, replace the driven faces with new ones.
REASSEMBLY
Reassemble the clutch shoe assembly and movable driven face in the reverse order of disassembly. Pay attention to the following points.
Install the bearing 2 in the fixed driven face 1 using the special tool.
09943-88211: Bearing installer
Securely install the circlip.
ENGINE 3-21
3-22 ENGINE
Install the needle roller bearing using the special tool.
09924-84521: Bearing installer
NOTE:
Face the stamped side of the needle roller bearing out.
Apply SUZUKI SUPER GREASE “A” between the sliding surface of the fixed driven face and movable driven face.
99000-25010: SUZUKI SUPER GREASE “A”
NOTE:
When installing the movable face to the fixed face, make sure that the oil seal is positioned properly.
Install the pins 1 at three places on the drive face hub.
Apply sufficient SUZUKI SUPER GREASE “A” to the cam where the pins are placed and to the surface of the driven face, as shown.
99000-25010: SUZUKI SUPER GREASE “A”
Position the two O-rings 2.
Install the movable driven face spring guide.
NOTE:
Remove any grease from the movable driven face spring guide, after installation.
Hold the clutch shoe assembly using the special tools and then tighten the clutch shoe nut to the specified torque.
09930-40113: Rotor holder
09930-40131: Rotor holder attachment
Clutch shoe nut: 50 N·m (5.0 kgf-m)
ENGINE 3-23
MOVABLE DRIVE FACE
1 Movable drive face
2 Roller
3 Movable drive plate
4 Damper
5 Movable drive face cover
6 Spacer
7 Spacer
8 Drive belt
9 Fixed drive face
0 Washer
A Kick starter
B Concave washer
A Kick starter nut
ITEM
A
N·m kgf-m
50 5.0
DISASSEMBLY
Remove the movable drive face cover 1 and movable drive plate 2.
DRIVE FACE
Inspect the belt contact surface of the drive faces for wear, scratches or any abnormalities. If any damages are found, replace the drive face with a new one.
1
2
3-24 ENGINE
ROLLER AND SLIDING SURFACE
Inspect each roller and its sliding surface for wear or damage. If any damages are found, replace the rollers as a set.
DRIVE BELT
Remove the drive belt and check for cracks, wear and separation and measure the drive belt width with vernier calipers. If any damages are found or if the width of the drive belt is less than the service limit, replace the drive belt with a new one.
Drive belt width
Service Limit: 17.4 mm
Always keep the drive belt away from grease, oil, etc.
REASSEMBLY
Mount the three dampers 1 on the movable drive plate 2 and install it onto the movable drive face.
Install the movable drive face cover 3.
NOTE:
Make sure that the movable drive plate is fully positioned inside the movable drive face, otherwise the rollers may fall out.
Insert the spacer 4.
ENGINE 3-25
KICK STARTER
1 Spacer
2 Kick starter shaft
3 Kick starter spring
4 Clutch cover
5 Dowel pin
6 Gasket
7 Gasket
8 Kick starter lever
9 Kick starter drive gear
DISASSEMBLY
Remove the kick starter driven gear 1, kick starter shaft spring 2, and kick starter shaft 3.
2
3
1
REASSEMBLY
Apply SUZUKI SUPER GREASE “A” onto the inside of the kick starter shaft spacer.
99000-25010: SUZUKI SUPER GREASE “A”
3-26 ENGINE
Apply a light coat of SUZUKI SUPER GREASE “A” onto the end of the kick starter shaft.
99000-25010: SUZUKI SUPER GREASE “A”
Install the kick starter spring and hook its end 1 onto the clutch cover boss 2.
2
1
Apply SUZUKI SUPER GREASE “A” onto the shaft and gear of the kick starter drive gear.
99000-25010: SUZUKI SUPER GREASE “A”
Install the kick starter drive gear.
BEARINGS
Wash the bearing with a cleaning solvent and lubricate it with motor oil before inspection. Rotate the inner race and check to see that it turns smoothly. If it does not turn quietly and smoothly, or if there are signs of any abnormalities, the bearing is defective and must be replaced with a new one.
REAR AXLE SHAFT BEARING
Remove the bearing retainer.
Play
Play
Remove the rear axle shaft bearing using the special tool.
09921-20220: Bearing remover set
Replace the removed bearing with a new one.
Install the rear axle shaft bearing using the special tool.
09913-70210: Bearing installer set
RIGHT DRIVESHAFT BEARING AND IDLE SHAFT BEARING
Remove the right driveshaft bearing and idle shaft bearing using the special tools.
09921-20210: Bearing remover
09930-30102: Sliding hammer
Replace the removed bearings with new ones.
Install the right driveshaft bearing and idle shaft bearing using the special tool.
09913-70210: Bearing installer set
LEFT DRIVESHAFT BEARING
Remove the left driveshaft bearing using the special tool.
09921-20220: Bearing remover set
Replace the removed bearing with a new one.
Install the left driveshaft bearing using the special tool.
09913-70210: Bearing installer set
ENGINE 3-27
3-28 ENGINE
RIGHT CRANKSHAFT BEARING
Remove the right crankshaft bearings using the special tools.
09923-73210: Bearing remover
09930-30102: Sliding hammer
Replace the removed bearing with a new one.
Install the right crankshaft bearing using the special tool.
09913-70210: Bearing installer set
LEFT CRANKSHAFT BEARING
Remove the left crankshaft bearing using the special tools.
09923-74510: Bearing remover
09930-30102: Sliding hammer
Replace the removed bearing with a new one.
Install the left crankshaft bearing using the special tool.
09913-70210: Bearing installer set
OIL SEALS
Damage to the lip of the oil seal may result in leakage of the airfuel mixture or gear oil. Inspect the oil seal and if it is damaged, replace it with a new one.
Install the oil seals into the crankcase and gearbox cover, as shown below.
Replace the removed oil seals with new ones.
Apply SUZUKI SUPER GREASE “A” to the lip of the oil seals.
99000-25010: SUZUKI SUPER GREASE “A”
Be sure to apply THREAD LOCK “1342” to the outer surfaces of the right and left crankshaft oil seals to prevent them from moving.
99000-32050: THREAD LOCK “1342”
REAR AXLE SHAFT OIL SEAL
Remove the rear axle shaft bearing. ( 3-26)
Remove the rear axle shaft oil seal from the gearbox cover using the special tool.
09913-50121: Oil seal remover
Replace the removed oil seal with a new one.
Install the rear axle shaft oil seal into the gearbox cover, slowly, using the special tool.
09913-70210: Bearing installer set
DRIVE SHAFT OIL SEAL
Remove the drive shaft oil seal from the left crankcase using the special tool.
09913-50121: Oil seal remover
Replace the removed oil seal with a new one.
ENGINE 3-29
3-30 ENGINE
Install the drive shaft oil seal into the left crankcase, slowly, using the special tool.
09913-70210: Bearing installer set
CRANKSHAFT OIL SEALS
Remove the crankshaft oil seals from the left and right crankcase, using the special tool.
09913-50121: Oil seal remover
Replace the removed oil seals with new ones.
Install the crankshaft oil seal into the right crankcase, slowly, using the special tool.
09913-70210: Bearing installer set
NOTE:
Align the oil seal with the edge
A
of the crankcase, as shown.
Install the left crankshaft oil seals using the special tool after installing the crankshaft to the crankcase. ( 3-33)
ENGINE MOUNTING BUSHINGS
Inspect each engine mounting bushings 1 and 2 for damage.
If any damage is found, replace the engine mounting bushing with a new one.
Press out the engine mounting bushings in a vise using two steel tubes of the appropriate size, as shown.
Replace the removed bushing with a new one.
Crankcase
Front side
Install the engine mounting bushings using two steel tubes of the appropriate size and a vise. Press the mounting bushings 1 and 2 into the crankcase holes, as shown.
NOTE:
The knurled end
3
should face in. Projections
A
and
B
should be aligned evenly.
Crankcase
Rear side
ENGINE 3-31
Crankcase
0.5 mm
0.5 mm
Crankcase
0.5 mm
0.5 mm
3-32 ENGINE
ENGINE REASSEMBLY
Reassemble the engine in the reverse order of disassembly. The following steps require special attention or precautionary measures should be taken.
NOTE:
Apply engine oil to each running and sliding part before reassembling.
CRANKSHAFT
Mount the crankshaft into the right crankcase by pulling its right end into the crankcase using the special tools.
09910-32812: Crankshaft installer
09910-20116: Conrod holder
Never fit the crankshaft into the crankcase by striking it with a plastic hammer. Always use the special tool, otherwise the crankshaft may be misaligned.
CRANKCASE
Install the two dowel pins 1 and new gaskets 2.
Install the left crankcase onto the right crankcase.
Tighten the crankcase bolts.
NOTE:
After the crankcase bolts have been tightened, make sure that the crankshaft rotates smoothly.
If the crankshaft does not rotate smoothly, try to free it by tapping it with a plastic hammer.
1
1
2
Install the left crankshaft inner oil seal 1 using the special tool.
09941-74910: Bearing installer
Apply SUZUKI SUPER GREASE “A” (approximately 10 g) to the oil pump drive gear (on the crankshaft surface side).
99000-25010: SUZUKI SUPER GREASE “A”
28.5 mm
ENGINE 3-33
Install the left crankshaft outer oil seal using the special tool.
09913-70210: Bearing installer set
3-34 ENGINE
REAR AXLE SHAFT AND TRANSMISSION
1 Crankcase
2 Gearbox cover
3 Rear axle shaft/final driven gear
4 Idle shaft/gear
5 Washer
6 Washer
7 Drive shaft
Install the idle shaft/gear 1, with the thrust washer 2, into the gearbox.
Install the rear axle shaft/final driven gear 3.
Install the thrust washer 4 and the O-ring 5.
5
4
3
Install the driveshaft 1 and dowel pins 2.
2
ENGINE 3-35
2
1
Install the gearbox cover.
Tighten the bolts, a little at a time, diagonally.
Apply a light coat of SUZUKI SUPER GREASE “A” onto the pivoting surface of the brake cam, and then install the brake cam into the crankcase.
99000-25010: SUZUKI SUPER GREASE “A”
Position the brake cam so that the punch mark A faces the rear axle shaft.
A
3-36 ENGINE
Align the tang 1 on the brake lining wear indicator plate 2 with the cutaway 3 on the brake cam. Then, slide the brake lining wear indicator plate onto the brake cam.
Install the return spring and brake cam lever onto the brake cam and tighten the brake cam lever nut to the specified torque.
Brake cam lever nut: 10 N·m (1.0 kgf-m)
Install the brake shoes and rear wheel.
Tighten the rear axle nut to the specified torque.
NOTE:
Apply final gear oil (10W-40) to the axle nut before tightening it.
Rear axle nut: 120 N·m (12.0 kgf-m)
GENERATOR
Remove any grease from the tapered portion of the crankshaft and also from the generator rotor.
Install the key 1, stator coil 2, and pickup coil 3.
2
1
3
Apply THREAD LOCK SUPER “1322” to the generator rotor nut and then tighten it to the specified torque using the special tool.
99000-32110: THREAD LOCK SUPER “1322”
09930-40113: Rotor holder
Generator rotor nut: 40 N·m (4.0 kgf-m)
STARTER PINION AND STARTER GEAR
Tighten the final gear oil drain bolt 1 to the specified torque.
Final gear oil drain bolt: 5.5 N·m (0.55 kgf-m)
Add final gear oil until it flows from the final gear oil level hole 2.
Final gear oil quantity: 130 ml
Tighten the final gear oil level bolt to the specified torque.
Oil level bolt: 12 N·m (1.2 kgf-m)
Apply SUZUKI SUPER GREASE “A” onto the starter pinion shaft and install the starter pinion gear assembly 3.
99000-25010: SUZUKI SUPER GREASE “A”
Insert the dowel pins 4.
1
2
ENGINE 3-37
Install the starter idle gear cap 5.
Install the starter driven gear 6 onto the left crankshaft.
NOTE:
The convex side of the starter driven gear should face out.
3-38 ENGINE
DRIVE BELT
Insert the drive belt, as low as possible, between the clutch shoe/movable driven face while pulling out the driven face to provide the maximum drive belt clearance.
The drive belt contact surface of the driven face should be thoroughly cleaned.
Thoroughly clean the clutch housing and position it over the clutch shoe assembly.
Hold the clutch housing using the special tool, and tighten the clutch housing nut to the specified torque.
09930-40113: Rotor holder
Clutch housing nut: 50 N·m (5,0 kgf-m)
Install the movable drive face onto the crankshaft, as shown.
NOTE:
Thoroughly clean the drive belt contact surface.
Hold the generator rotor using the special tool, and tighten the kick starter nut to the specified torque.
09913-40113: Rotor holder
Kick starter nut: 50 N·m (5.0 kgf-m)
Turn the fixed drive face by hand, until the drive belt is properly seated and both the drive and driven faces rotate together smoothly and without slipping.
Install the dowel pins 1 and new gaskets 2.
Install the clutch cover 3 and kick starter lever 4.
PISTON
Install the piston rings onto the piston.
1st: Keystone ring
2nd: Rectangular ring and expander ring
NOTE:
The piston rings should be installed with the mark facing up.
Position the piston ring gaps, as shown. Before inserting the piston into the cylinder, check that the gaps are properly positioned.
1
2
ENGINE 3-39
2
1
3
4
CORRECT INCORRECT
Securely install the circlip 1.
NOTE:
The arrow mark
2
on the piston crown should be pointing towards the exhaust side.
Apply engine oil onto the piston pin, and then install the piston.
3-40 ENGINE
CYLINDER
Apply engine oil onto the piston and cylinder wall surfaces, and then install the cylinder over the piston carefully.
CYLINDER HEAD
Tighten the cylinder head nuts diagonally, as shown, and to the specified torque.
Cylinder head nut: 10 N·m (1.0 kgf-m)
OIL PUMP GEAR
Apply SUZUKI SUPER GREASE “A” onto the oil pump gear, and then install it.
99000-25010: SUZUKI SUPER GREASE “A”
INTAKE PIPE
Install the intake pipe and tighten the bolts securely.
NOTE:
Be sure to use the special twist-off bolt
A
as shown.
EXHAUST PIPE/MUFFLER
Tighten the exhaust pipe mounting nut and bolt to the specified torque.
Exhaust pipe mounting nut and bolt: 10 N·m (1.0 kgf-m)
A
FUEL AND LUBRICATION SYSTEM
FUEL AND LUBRICATION SYSTEM
4-1
CONTENTS
FUEL VALVE .................................................................................................... 4- 2
FUEL TANK AND OIL TANK ........................................................................... 4- 3
REMOVAL ................................................................................................... 4- 3
REMOUNTING ............................................................................................ 4- 4
FUEL TANK CUSHIONS ............................................................................. 4- 5
CARBURETOR ................................................................................................ 4- 6
CONSTRUCTION ........................................................................................ 4- 6
I. D. NO. LOCATION .................................................................................... 4- 6
SPECIFICATIONS ....................................................................................... 4- 7
REMOVAL ................................................................................................... 4- 8
DISASSEMBLY ........................................................................................... 4- 8
CLEANING .................................................................................................. 4-11
INSPECTION AND ADJUSTMENT ............................................................ 4-11
REASSEMBLY ............................................................................................ 4-12
REMOUNTING ............................................................................................ 4-12
OIL PUMP ........................................................................................................ 4-13
AIR BLEEDING ........................................................................................... 4-13
DISCHARGE RATE CHECK ....................................................................... 4-13
4
4-2 FUEL AND LUBRICATION SYSTEM
FUEL VALVE
When the engine has started, negative pressure (vacuum) is generated at the intake port. The negative pressure causes the fuel valve diaphragm to compress its spring, opening the fuel passageway and allowing the fuel to flow to the carburetor.
When the engine has stopped, the spring pushes against the valve, closing the fuel passageway, and stopping the flow of fuel to the carburetor.
To carburetor
Negative pressure
Air vent hose
From fuel tank
FUEL TANK AND OIL TANK
REMOVAL
Gasoline is highly flammable and explosive.
Keep heat, sparks, and flames away from gasoline.
Remove the frame cover. ( 5-4 and 5-5)
Disconnect the turn signal light lead wires 1 and license plate light coupler 2.
FUEL AND LUBRICATION SYSTEM 4-3
1
2
Disconnect the fuel level indicator switch coupler.
Disconnect the air vent hose 3 and fuel hose 4.
3
Remove the lower fuel tank cover mounting bolts.
4
4-4 FUEL AND LUBRICATION SYSTEM
Remove the fuel tank cap 1 and fuel tank 2.
NOTE:
After removing the fuel tank, reinstall the fuel tank cap.
2 1
Disconnect the oil hose 3, oil level indicator switch coupler 4, and remove the oil tank 5.
REMOUNTING
Remount the fuel tank and oil tank in the reverse order of removal.
3
5
4
FUEL AND LUBRICATION SYSTEM 4-5
FUEL TANK CUSHIONS
Cushion
A
80 mm
13 mm
Cushion
60 mm
75 mm
B
15 mm
20 mm
VIEW
A
45˚
VIEW
B
4-6 FUEL AND LUBRICATION SYSTEM
CARBURETOR
CONSTRUCTION
I. D. NO. LOCATION
The carburetor has an I. D. number
A stamped on its body according to its specifications.
1 Top cap
2 Throttle valve spring
3 Jet needle
4 Throttle valve
5 Thermoelement
6 Carburetor body
7 Pilot air screw
8 Throttle stop screw
9 Needle valve
0 Float pin
A Float
B Needle jet
C Needle jet holder
D Slow jet
E Main jet
F Float chamber
G Thermoswitch
A Carburetor heater
ITEM
A
N·m kgf-m
3 0.3
A
SPECIFICATIONS
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Slow jet
Air screw
Throttle cable play
(M.J.)
(J.N.)
(S.J.)
(A.S.)
FUEL AND LUBRICATION SYSTEM 4-7
SPECIFICATION
KEIHIN PWS14
14 mm
30F0
1 900 ± 200 r/min
5.1 ± 0.5 mm
# 65
N5GJ-2nd
# 42
2 turns back
2 – 4 mm
4-8 FUEL AND LUBRICATION SYSTEM
REMOVAL
Remove the trunk. ( 5-4)
Remove the clamps, disconnect the thermoelement coupler 1 and carburetor heater lead wire 2.
1
2
Disconnect the vacuum hose 3 and fuel hose 4.
3
4
Loosen the carburetor clamp screw and remove the carburetor mounting bolts.
Remove the top cap.
DISASSEMBLY
Remove the throttle cable from the slit in the throttle valve, and then remove the throttle valve 1 along with the jet needle and throttle valve spring 2.
1
2
Separate the jet needle 1 and throttle valve 2.
FUEL AND LUBRICATION SYSTEM 4-9
1
2
Remove the each carburetor hoses.
Remove the float chamber 3.
3
Remove the float 4 and needle valve 5 by removing the float pin 6.
When removing the float pin, be careful not to damage the carburetor body and float.
6
5
4
Remove the main jet 7, needle jet holder 8, needle jet 9, and pilot jet 0.
0
7
8
9
Remove the throttle stop screw A and pilot air screw B.
Do not use wire to clean the passageways, valve seat, and jets. Use compressed air only.
B
A
4-10 FUEL AND LUBRICATION SYSTEM
Remove the thermoelement cover 1 and remove the thermoelement 2.
1
2
Do not disassemble the thermoelement. It is not serviceable.
Remove the carburetor heater.
CLEANING
Some carburetor cleaning chemicals, especially diptype soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions for proper use, handling and storage.
Clean all jets with a spray-type carburetor cleaner and dry them using compressed air.
Clean all circuits of the carburetor thoroughly––not just the perceived problem area. Clean the circuits in the carburetor body with a spray-type cleaner. If necessary, soak each circuit in a dip-type cleaning solution to loosen dirt and varnish.
Dry the carburetor body using compressed air.
Do not use wire to clean the passageways, valve seat, and jets. If the components cannot be cleaned with a spray-type cleaner it may be necessary to soak them in a dip-type cleaning solution. Always follow the chemical manufacturer’s instructions for proper use and cleaning of the carburetor components.
After cleaning, reassemble the carburetor with new O-rings.
Replace the removed O-rings with new ones.
INSPECTION AND ADJUSTMENT
Check the following items for any damage or clogging. If any damages are found, replace the damaged parts with new ones.
Main jet
Pilot jet
Throttle valve
Float
Needle jet
Pilot air screw
Thermoelement (
Carburetor heater (
6-21)
6-22)
Needle valve
Pilot outlet and bypass holes
NEEDLE VALVE
If foreign matter is caught between the valve seat and the needle valve, the gasoline will continue flowing and overflow. If the valve seat and needle valve are worn beyond the permissible limits, similar trouble will occur. Conversely, if the needle valve sticks, the gasoline will not flow into the float chamber. Clean the float chamber and float parts with gasoline. If the needle valve is worn, as shown in the illustration, replace it with a new valve seat.
Clean the fuel passage of the mixing chamber with compressed air.
FUEL AND LUBRICATION SYSTEM 4-11
CORRECT INCORRECT
4-12 FUEL AND LUBRICATION SYSTEM
FLOAT HEIGHT ADJUSTMENT
To check the float height, turn the carburetor upside down. Measure the float height
A while the float arm is just contacting the needle valve using vernier calipers. Bend the tongue as necessary to bring the float height
A to the specified value.
Float height
A
Standard: 5.1 ± 0.5 mm
09900-20101: Vernier calipers
REASSEMBLY
Reassemble the carburetor in the reverse order of disassembly.
Pay attention to the following points:
Tighten the carburetor heater to the specified torque.
Carburetor heater: 3 N·m (0.3 kgf-m)
Adjust the pilot air screw. ( 4-7)
Install the throttle valve with the top cap.
Align the slit 1 on the throttle valve with the projection 2 on the carburetor body.
1
REMOUNTING
Remount the carburetor in the reverse order of removal. Pay attention to the following points:
After all of the work has been completed, install the carburetor onto the motorcycle and refer to the following section to adjust the respective items to specification.
ENGINE IDLE SPEED .............................................
THROTTLE CABLE PLAY .......................................
2-7
2-7
A
2
OIL PUMP
AIR BLEEDING
Whenever air leaks into the oil pipe from the oil tank or the oil pump is removed, the oil pump must be bled of any air.
Hold the motorcycle in a stationary position. Loosen the screw 1 to bleed the air. After all of the air has been bled, tighten the screw.
FUEL AND LUBRICATION SYSTEM 4-13
1
DISCHARGE RATE CHECK
Use the CCI oil gauge to check the oil pump discharge rate.
Measure the amount of oil that the oil pump draws during the procedure.
Remove the trunk. ( 5-4)
Fill the CCI oil gauge with SUZUKI CCI SUPER OIL. Connect the oil gauge to the suction side of the oil pump.
Run the engine at 3 000 r/min.
Keep the engine speed at 3 000 r/min and allow the pump to draw for five minutes. The measurement on the oil gauge should be within specification.
09900-21602: CCI oil gauge
Oil discharge amount:
0.8 – 1.2 ml at 3 000 r/min for 5 minutes
Be sure to place the motorcycle on the center stand.
Do not touch the rear wheel while the engine is running.
After checking the oil pump, refer to the following section to adjust the respective item to specification.
ENGINE IDLE SPEED .............................................
2-7
CHASSIS 5-1
CHASSIS
CONTENTS
EXTERIOR PARTS ...................................................................................................... 5- 2
CONSTRUCTION .................................................................................................... 5- 2
REMOVAL ............................................................................................................... 5- 3
REMOUNTING ........................................................................................................ 5- 5
FRONT WHEEL ........................................................................................................... 5- 6
CONSTRUCTION .................................................................................................... 5- 6
REMOVAL ............................................................................................................... 5- 6
INSPECTION AND DISASSEMBLY ....................................................................... 5- 7
REASSEMBLY AND REMOUNTING ..................................................................... 5- 8
FRONT BRAKE ........................................................................................................... 5-10
CONSTRUCTION .................................................................................................... 5-10
BRAKE PADS REPLACEMENT ............................................................................. 5-11
BRAKE FLUID REPLACEMENT ............................................................................ 5-12
BRAKE CALIPER REMOVAL AND DISASSEMBLY ............................................ 5-12
BRAKE CALIPER INSPECTION ............................................................................ 5-13
BRAKE CALIPER REASSEMBLY AND REMOUNTING ...................................... 5-14
BRAKE DISC INSPECTION ................................................................................... 5-15
MASTER CYLINDER REMOVAL AND DISASSEMBLY ....................................... 5-15
MASTER CYLINDER INSPECTION ....................................................................... 5-16
MASTER CYLINDER REASSEMBLY AND REMOUNTING ................................. 5-17
FRONT SUSPENSION ................................................................................................ 5-18
CONSTRUCTION .................................................................................................... 5-18
REMOVAL AND DISASSEMBLY ........................................................................... 5-18
INSPECTION ........................................................................................................... 5-20
REASSEMBLY AND REMOUNTING ..................................................................... 5-20
HANDLEBAR COVERS AND SPEEDOMETER ASSEMBLY .................................... 5-22
CONSTRUCTION .................................................................................................... 5-22
REMOVAL ............................................................................................................... 5-23
REMOUNTING ........................................................................................................ 5-24
STEERING STEM ........................................................................................................ 5-25
CONSTRUCTION .................................................................................................... 5-25
REMOVAL AND DISASSEMBLY ........................................................................... 5-25
INSPECTION ........................................................................................................... 5-27
REASSEMBLY AND REMOUNTING ..................................................................... 5-28
REAR WHEEL, REAR BRAKE, AND REAR SHOCK ABSORBER .......................... 5-30
CONSTRUCTION .................................................................................................... 5-30
REMOVAL AND DISASSEMBLY ........................................................................... 5-30
INSPECTION ........................................................................................................... 5-31
REASSEMBLY AND REMOUNTING ..................................................................... 5-32
TIRES AND WHEELS .................................................................................................. 5-33
TIRE REMOVAL ...................................................................................................... 5-33
INSPECTION ........................................................................................................... 5-33
INSTALLATION ....................................................................................................... 5-34
5
5-2 CHASSIS
EXTERIOR PARTS
CONSTRUCTION
REMOVAL
LEG SHIELD
Remove the battery. ( 6-30)
Remove the side leg shields 1.
Remove the frame cover.
Remove the footboard 2.
Remove the cover 3.
Remove the front leg shield mounting screws.
3
1
CHASSIS 5-3
2
Disconnect the headlight lead wires 4 and remove the front leg shield 5.
4
5
5-4 CHASSIS
Remove the lower leg shield 1.
Remove the ignition switch cap 2.
1
2
Remove the leg shield 3.
SEAT
Remove the seat 1.
FRAME COVER
Remove the seat.
Remove the side leg shield. ( 5-3)
Remove the trunk 1 and fuel tank cap 2.
3
1
1
2
Remove the upper fuel tank cover 1.
After removing the upper fuel tank cover, reinstall the fuel tank cap.
1
Remove the passenger grab handle 2.
CHASSIS 5-5
2
Remove the frame cover mounting screw.
Disconnect the seat lock cable 3, brake light/taillight lead wires 4, and remove the frame cover 5.
4
3
5
REMOUNTING
Remount the leg shield, seat, and frame cover in the reverse order of removal.
5-6 CHASSIS
FRONT WHEEL
CONSTRUCTION
1 Front axle
2 Spacer
3 Brake disc
4 Bearing
5 Front wheel
6 Spacer
7 Speedometer gearbox
A Front axle nut
B Brake disc bolt
ITEM
A
B
N·m
42
23
kgf-m
4.2
2.3
REMOVAL
Disconnect the speedometer cable 1.
Remove the front axle nut 2.
Raise the front wheel off the ground by raising the motorcycle with a jack or wooden block.
Remove the front axle and then the front wheel and spacer.
1
Remove the speedometer gearbox.
2
CHASSIS 5-7
Remove the brake disc.
INSPECTION AND DISASSEMBLY
SPEEDOMETER GEARBOX DUST SEAL
Inspect the speedometer gearbox dust seal for damage. If any damage is found, replace the speedometer gearbox with a new one.
WHEEL BEARINGS
Inspect the play of the wheel bearings by hand while they are in the wheel. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. If any abnormal noise occurs, or rough movement is noted, replace the wheel bearings with new ones.
Remove the wheel bearings as follows:
Insert the bearing remover attachment 1 into the wheel bearing.
Insert the wedge bar 2 from the opposite side and lock it into the slit of the bearing remover attachment.
Drive out the wheel bearing by striking the wedge bar.
09941-50111: Bearing remover
Replace the removed bearings with new ones.
2
Play
1
Play
5-8 CHASSIS
FRONT WHEEL
Make sure that the wheel runout (axial and radial) does not exceed the service limit when checked as shown. An excessive amount of runout is usually due to worn or loose wheel bearings and can be corrected by replacing the bearings. If bearing replacement fails to reduce the runout, replace the wheel with a new one.
Wheel rim runout (axial and radial)
Service Limit: 2.0 mm
FRONT AXLE
Measure the front axle runout using the dial gauge. If the runout exceeds the service limit, replace the front axle with a new one.
09900-20606: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
09900-21304: V-block set (100 mm)
Wheel axle runout
Service Limit: 0.25 mm
TIRE ............................................................................
2-12
REASSEMBLY AND REMOUNTING
Reassemble and remount the front wheel in the reverse order of removal and disassembly. Pay attention to the following points:
WHEEL BEARINGS
Apply SUZUKI SUPER GREASE “A” to the wheel bearings.
99000-25010: SUZUKI SUPER GREASE “A”
Install the wheel bearings using the special tool.
09924-84521: Bearing installer set
First, install the left wheel bearing, and then install the right wheel bearing. The sealed cover on the wheel bearing must face out.
CHASSIS 5-9
1 Bearing (L)
2 Spacer
3 Clearance
4 Bearing (R)
BRAKE DISC
Make sure that the brake disc is clean and free of any grease.
Apply THREAD LOCK SUPER “1360” to the brake disc mounting bolts and tighten them to the specified torque.
99000-32130: THREAD LOCK SUPER “1360”
Brake disc mounting bolt: 23 N·m (2.3 kgf-m)
SPEEDOMETER GEARBOX
Apply SUZUKI SUPER GREASE “A” to the teeth of the speedometer gear before installing the speedometer gearbox.
99000-25010: SUZUKI SUPER GREASE “A”
Align the grooves 1 on the speedometer gearbox with the lugs 2 on the wheel hub.
FRONT WHEEL
Tighten the front axle nut to the specified torque.
Front axle nut: 42 N·m (4.2 kgf-m)
2
1
5-10 CHASSIS
FRONT BRAKE
CONSTRUCTION
1 Cap
2 Diaphragm
3 Master cylinder
4 Piston set
5 Push rod
6 Dust boot
7 Brake hose
8 Caliper
9 Piston
0 Piston and dust seal
A Shim
B Pad set
C Pad mounting pin
D O-ring
A Master cylinder mounting bolt
B Brake hose union bolt
C Air bleeder valve
D Brake caliper housing bolt
E Brake caliper mounting bolt
ITEM
A
B
C
D
E
N·m kgf-m
10 1.0
23
7.5
26
32
2.3
0.75
2.6
3.2
The brake system is filled with an glycol-based brake fluid, which is classified DOT 4. Do not use or mix other types of brake fluid, such as silicone-based and petroleum-based brake fluids when refilling the brake system, otherwise serious damage to the brake system will result.
Do not use any brake fluid taken from old, used, or unsealed containers.
Do not reuse brake fluid left over from the last servicing or which has been stored for a long period of time.
When storing brake fluid, be sure to seal the container completely and keep it out of the reach of children.
When replenishing brake fluid, be sure not to get any dust or other foreign materials in the fluid.
When washing brake components, always use new brake fluid. Do not use cleaning solvent.
A contaminated brake disc or brake pad reduces braking performance. Discard contaminated pads and clean the brake disc with high-quality brake cleaner or a neutral detergent.
Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber material, etc.
CHASSIS 5-11
BRAKE PADS REPLACEMENT
Remove the brake caliper mounting bolts 1.
1
Remove the brake pad mounting pins 2 and brake pads.
Do not operate the brake lever during or after brake pad removal.
Measure the thickness A of the brake pads. If the brake pad thickness is below the service limit, replace the brake pads with new ones.
Brake pad thickness A
Service Limit: 0.7 mm
Replace the brake pads as a set, otherwise braking performance will be adversely affected.
Install the new brake pads and shims.
Be sure to properly install the shims 3 as shown in
the illustration.
Tighten the brake caliper mounting bolts 4 to the specified torque.
Brake caliper mounting bolt: 26 N·m (2.6 kgf-m)
NOTE:
After replacing the brake pads, pump the brake lever a few times to check for proper brake operation, and then check the brake fluid level.
4
3
2
5-12 CHASSIS
BRAKE FLUID REPLACEMENT
Place the motorcycle on a level surface and keep the handlebar 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.
Specification and classification: DOT 4
Connect a clear hose to the air bleeder valve and insert the other end of the hose into a receptacle.
Loosen the air bleeder valve and pump the brake lever until the old brake fluid is completely out of the brake system.
Close the air bleeder valve and disconnect the clear hose. Fill the reservoir with new brake fluid to the upper end of the inspection window.
Bleed air from the brake fluid circuit. ( 2-10)
BRAKE CALIPER REMOVAL AND
DISASSEMBLY
Disconnect the brake hose from the brake caliper by removing the brake hose union bolt 1 and allow the brake fluid to drain into a suitable receptacle.
Slightly loosen the brake caliper housing bolts 2.
Remove the brake caliper by removing the brake caliper mounting bolts 3.
Never reuse the brake fluid left over from previous servicing or which has been stored for long period of time, otherwise serious damage to the brake system will result.
Brake fluid, if it leaks, will interfere with safe running and discolor painted surfaces. Check the brake hose and hose joints for cracks and oil leakage.
3
2
1
Remove the brake pads. ( 5-11)
Remove the brake caliper housing bolts.
Separate the brake caliper.
Remove the O-ring.
Do not reuse the O-ring to prevent fluid leakage.
Place a rag over the brake caliper pistons to prevent them from popping out, and then force out the piston using compressed air.
Do not use extremely high pressure air to remove the brake caliper pistons, otherwise damage to the pistons will result.
Remove the dust seals and piston seals.
Do not reuse the dust seals and piston seals to prevent fluid leakage.
BRAKE CALIPER INSPECTION
BRAKE CALIPER
Inspect the brake caliper cylinder wall for nicks, scratches, or other damage. If any damages are found, replace the brake caliper with a new one.
BRAKE CALIPER PISTON
Inspect the brake caliper pistons for any scratches or other damage. If any damages are found, replace the piston with a new one.
CHASSIS 5-13
5-14 CHASSIS
BRAKE CALIPER REASSEMBLY AND
REMOUNTING
Reassemble and remount the brake caliper in the reverse order of removal and disassembly. Pay attention to the following points:
Wash the caliper bores and brake caliper pistons with the specified brake fluid. Thoroughly wash the dust seal grooves and piston seal grooves.
Specification and classification: DOT 4
Wash the brake caliper components with new brake fluid before reassembly.
When washing the components, use the specified brake fluid. Never use different types of fluid or cleaning solvents such as gasoline, kerosine etc.
Do not wipe the brake fluid off after washing the components.
Replace the removed piston seals and dust seals with new ones.
Apply brake fluid to all of the seals, brake caliper bores and pistons before reassembly.
Tighten the brake caliper housing bolts 1, brake caliper mounting bolts 2, and the brake hose union bolt 3 to the specified torque.
Brake caliper housing bolt: 32 N·m (3.2 kgf-m)
Brake caliper mounting bolt: 26 N·m (2.6 kgf-m)
Brake hose union bolt: 23 N·m (2.3 kgf-m)
NOTE:
Before remounting the brake caliper, push the brake caliper pistons all the way into the brake caliper.
Bleed air from the brake system after reassembling the brake caliper. ( 2-10)
2
1
3
CHASSIS 5-15
BRAKE DISC INSPECTION
Remove the front wheel. ( 5-6)
Check the brake disc for cracks or damage and measure the thickness using the micrometer. If the thickness is less than the service limit or if any damages are found, replace the brake disc with a new one.
09900-20205: Micrometer (0 – 25 mm)
Brake disc thickness
Service Limit: 3.5 mm
Measure the runout using the dial gauge. If the runout exceeds the service limit, replace the brake disc with a new one.
09900-20606: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
Brake disc runout
Service Limit: 0.30 mm
If either measurement exceeds the service limit, replace the brake disc with a new one. ( 5-7)
Install the front wheel. ( 5-9)
MASTER CYLINDER REMOVAL AND
DISASSEMBLY
Remove the handlebar cover. ( 5-23 and 5-24)
Place a rag underneath the brake hose union bolt on the master cylinder to catch any spilt brake fluid.
Remove the brake hose union bolt and disconnect the brake hose/master cylinder joint.
Immediately wipe off any brake fluid contacting any part of the motorcycle. The brake fluid reacts chemically with paint, plastics, rubber materials, etc., and will damage them severely.
Disconnect the front brake light switch lead wires 1.
Remove the master cylinder assembly by removing the clamp bolts 2.
1
2
5-16 CHASSIS
Remove the brake lever and brake light switch.
Remove the dust boot and push rod.
Remove the circlip.
Remove the piston/secondary cup 1 and return spring 2.
Remove the master cylinder reservoir cap 3 and diaphragm 4.
Drain the brake fluid.
MASTER CYLINDER INSPECTION
MASTER CYLINDER
Inspect the master cylinder bore for any scratches or other damage. If any damages are found, replace the master cylinder with a new one.
3
4
2
1
PISTON
Inspect the piston surface for any scratches or other damage. If any damages are found, replace the piston with a new one.
RUBBER PARTS
Inspect the primary cup, secondary cup and dust seal for wear or damage. If any damages are found, replace the piston/secondary cup, and dust seal with new ones.
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:
Wash the master cylinder components with new brake fluid before reassembly.
Do not wipe the brake fluid off after washing the components.
When washing the components, use the specified brake fluid. Never use different types of fluid or cleaning solvents such as gasoline, kerosine, etc.
Apply brake fluid to the master cylinder bore and all of the master cylinder components before reassembly.
Specification and classification: DOT 4
When remounting the master cylinder on the handlebar, align the master cylinder holder’s mating surface 1 with the punch mark 2 on the handlebar, and then tighten the upper clamp bolt first.
Master cylinder clamp bolt: 10 N·m (1.0 kgf-m)
Tighten the brake hose union bolt to the specified torque.
Brake hose union bolt: 23 N·m (2.3 kgf-m)
Bleed air from the brake system after reassembling the master cylinder. ( 2-10)
2
1
CHASSIS 5-17
5-18 CHASSIS
FRONT SUSPENSION
CONSTRUCTION
1 Damper
2 Upper spring
3 Inner tube
4 Lower spring
5 Upper circlip
6 Bushing
7 Lower circlip
8 Dust seal
9 Brake caliper bracket
A Brake caliper bracket mounting bolt
ITEM
A
N·m
20
kgf-m
2.0
REMOVAL AND DISASSEMBLY
Remove the front wheel. (
Remove the brake caliper. (
5-6)
5-12)
Repeat following steps for each fork leg.
Remove the brake caliper bracket 1.
Remove the dust seal 2.
1
2
Remove the lower circlip 1.
Replace the removed lower circlip with a new one.
Remove the lower bushing 2.
NOTE:
When removing the lower bushing
2
, pull the inner tube
3
down.
Remove the upper circlip 4, lower spring 5, and inner tube 6.
Replace the removed upper circlip with a new one.
Remove the upper spring 7 and damper 8.
CHASSIS 5-19
1
3
2
4
6
5
8
7
5-20 CHASSIS
INSPECTION
FORK SPRING
Measure the fork spring free length. If the fork spring free length is shorter than the service limit, replace the fork spring with a new one.
Front fork spring free length
Service Limit: 122 mm
INNER TUBE
Inspect the inner tube sliding surface for any scuffing or damage. If any damages are found, replace the inner tube with a new one.
BUSHING
Inspect the bushing for wear or damage. If any damages are found, replace the bushing with a new one.
REASSEMBLY AND REMOUNTING
Reassemble and remount the front suspension in the reverse order of removal and disassembly. Pay attention to the following points:
DAMPER AND SPRING
Apply SUZUKI SUPER GREASE “A” (15 g) to the damper and springs.
99000-25010: SUZUKI SUPER GREASE “A”
When installing the upper spring 1 and damper 2, face
the smaller diameter end of the upper spring and the hollow end of the damper towards the wheel.
2
1
UPPER CIRCLIP
Install the circlip 1 into the groove 2.
Replace the upper circlip with a new one.
The rounded side on the circlip must face upward.
After installing the upper circlip, make sure that it is properly seated in the groove.
BUSHING
Install the lower bushing 3 using the special tool.
09940-52860: Front fork oil seal installer
LOWER CIRCLIP
Install the lower circlip 4 into the ring groove 5.
Replace the lower circlip with a new one.
The rounded side on the circlip must face upward.
After installing the lower circlip, make sure that it is properly seated in the groove.
Tighten the brake caliper bracket mounting bolt to the specified torque.
Brake caliper bracket mounting bolt: 20 N·m (2.0 kgf-m)
NOTE:
Before tightening the front axle nut, move the front fork up and down four or five times.
CHASSIS 5-21
1
2
3
4
5
5-22 CHASSIS
HANDLEBAR COVERS AND SPEEDOMETER ASSEMBLY
CONSTRUCTION
1 Front handlebar cover
2 Rear handlebar cover
REMOVAL
Remove the rear view mirrors 1.
Remove the front handlebar cover 2.
1
CHASSIS 5-23
2
Disconnect the front turn signal light lead wires.
Disconnect the speedometer cable 3 and speedometer couplers 4.
Remove the speedometer assembly 5.
4
3
Disconnect the handlebar switch couplers.
5
5-24 CHASSIS
Remove the rear handlebar cover 1.
REMOUNTING
Remount the handlebar covers and the speedometer assembly in the reverse order of removal.
94P50730
1
CHASSIS 5-25
STEERING STEM
CONSTRUCTION
1 Handlebar
2 Washer
3 Steering stem nut
4 Inner upper race
5 Inner lower race
6 Steel ball
7 Outer lower race
8 Steering stem
A Handlebar clamp nut
B Handlebar set bolt
C Steering stem locknut
ITEM
A
B
C
N·m
50
25
30
kgf-m
5.0
2.5
3.0
REMOVAL AND DISASSEMBLY
Remove the front leg shield and leg shield. (
Remove the master cylinder assembly. (
5-3 and 5-4)
5-15)
Remove the front suspension. ( 5-18 and 5-19)
Remove the handlebar cover and speedometer assembly.
( 5-23 and 5-24)
Remove the cable clamp.
Remove the front fender brace 1 and front fender 2.
1
2
5-26 CHASSIS
Remove the throttle cable 1 and throttle grip 2.
Remove the brake hose 3 and speedometer cable 4.
3
2
1
4
Remove the rear brake cable 5.
Disconnect the rear brake light switch lead wires 6.
5
6
Remove the handlebar.
Remove the steering stem locknut using the special tool.
09910-60611: Universal clamp wrench
CHASSIS 5-27
Remove the washer 1 and steering stem nut 2.
Remove the steering stem.
NOTE:
Hold the steering stem bracket to prevent it from falling.
Remove the upper and lower steel balls.
Steel balls
Upper : 25 pcs
Lower : 30 pcs
INSPECTION
Inspect the removed parts for the following abnormalities. If any damages are found, replace the respective part with a new one.
Steering race wear and brinelling
Worn and damaged steel balls
Distortion of steering stem or handlebar
Remove the outer lower race using a chisel.
2
1
Drive out the upper and lower races.
5-28 CHASSIS
REASSEMBLY AND REMOUNTING
Reassemble and remount the steering stem and handlebar in the reverse order of removal and disassembly. Pay attention to the following points:
UPPER AND LOWER RACES
Press in the upper and lower races using the special tool.
09941-34513: Steering inner race installer
STEEL BALLS
Apply SUZUKI SUPER GREASE “A” to the steering races when installing the upper and lower steel balls.
99000-25010: SUZUKI SUPER GREASE “A”
Steel balls
Upper : 25 pcs
Lower : 30 pcs
STEERING STEM
Tighten the steering stem nut 1, and then loosen it 1/8 – 1/4 of a turn.
NOTE:
This adjustment will vary from motorcycle to motorcycle. Make sure that the steering turns smoothly and easily; in both directions.
When installing the washer, align the tongue 2 of the washer with the groove 3 of the steering stem shaft.
1
2
3
Tighten the steering stem locknut to the specified torque using the special tool.
Steering stem locknut: 30 N·m (3.0 kgf-m)
09910-60611: Universal clamp wrench
Finger tighten the handlebar set bolt 1 and handlebar clamp nut 2, and then tighten them to the specified torque.
Handlebar set bolt: 25 N·m (2.5 kgf-m)
Handlebar clamp nut: 50 N·m (5.0 kgf-m)
2
CHASSIS 5-29
1
NOTE:
Hold the front fork legs, move them back and forth and make sure that the steering is not loose.
After performing the adjustment and installing the handlebar, “rock” the front wheel assembly forward and backward to ensure there is no play and the procedure was accomplished correctly.
Check the steering stem to make sure that it moves freely from left to right with its own weight. If play or stiffness is noticeable, readjust the steering stem nut.
5-30 CHASSIS
REAR WHEEL, REAR BRAKE, AND REAR SHOCK ABSORBER
CONSTRUCTION
1 Rear wheel
2 Brake shoe
3 Brake cam
4 Return spring
5 Brake lining wear indicator plate
6 Brake cam lever
7 Rear shock absorber
A Rear axle nut
B Rear brake cam lever nut
C Rear shock absorber upper mounting bolt
D Rear shock absorber lower mounting nut
REMOVAL AND DISASSEMBLY
REAR WHEEL AND BRAKE
Place the motorcycle on level ground.
Support the motorcycle using a jack or wooden block.
Remove the exhaust pipe/muffler assembly. ( 3-6)
Remove the rear wheel.
Remove the brake shoes.
ITEM
A
B
C
D
N·m
120
10
29
35
kgf-m
12.0
1.0
2.9
3.5
REAR SHOCK ABSORBER
Remove the frame cover. ( 5-4 and 5-5)
Remove the rear shock absorber.
INSPECTION
BRAKE DRUM
Inspect the brake drum and measure the brake drum I.D. to determine the extent of wear. If the measurement exceeds the service limit, replace the brake drum with a new one. The value of this limit is indicated inside the drum.
Brake drum I.D.
Service Limit: 120.7 mm
BRAKE SHOE
Inspect the brake shoes for wear or damage. If any wear or damages are found, replace the brake shoes as a set.
Replace the brake shoes as a set, otherwise braking performance will be adversely affected.
REAR SHOCK ABSORBER
Inspect the rear shock absorber for oil leakage or other damage.
If any oil leakages or damages are found, replace the rear shock absorber with a new one.
Do not attempt to disassemble the shock absorber. It is not serviceable.
TIRE ...........................................................................
2-12
CHASSIS 5-31
5-32 CHASSIS
REASSEMBLY AND REMOUNTING
Reassemble and remount the rear wheel, rear brake, and rear shock absorber in the reverse order of removal and disassembly. Pay attention to the following points:
Apply SUZUKI SUPER GREASE “A” to the brake cam and pin, and then install the brake shoes.
99000-25010: SUZUKI SUPER GREASE “A”
Be careful not to apply too much grease to the brake cam and pin. If grease gets on the lining, brake slippage will result.
Tighten the rear axle nut to the specified torque.
NOTE:
Apply final gear oil (10W-40) to the axle nut before tightening it.
Rear axle nut: 120 N·m (12.0 kgf-m)
Tighten the rear shock absorber upper mounting bolt 1 and lower mounting nut 2 to the specified torque.
Rear shock absorber upper mounting bolt:
29 N·m (2.9 kgf-m)
Rear shock absorber lower mounting nut:
35 N·m (3.5 kgf-m)
1
2
TIRES AND WHEELS
TIRE REMOVAL
The most critical factor of a tubeless tire is the seal between the wheel rim and the tire bead. Because of this, we recommended using a tire changer that can satisfy this sealing requirement and can make the operation efficient as well as functional.
For operating procedures, refer to the instructions supplied by the tire changer manufacturer.
NOTE:
When removing a tire for repair or inspection, be sure to mark the tire with chalk to indicate the tire position relative to the valve position.
Even though the tire is refitted to the original position after repairing the puncture, the tire may have to be balanced again since such a repair can cause imbalance.
INSPECTION
WHEELS
Clean and check each wheel for the following. If any item is observed, replace the wheel with a new one.
Distortion and crack
Nick or scratch on bead
Wheel rim runout
Wheel rim runout (axial and radial)
Service Limit: 2.0 mm
TIRES
Check each tire for the following. If any item is observed, replace the tire with a new one.
Nicks and rupture on sidewall
Tread remaining depth
Separation of cord
Abnormal, uneven wear on tread
Surface damage on bead
Localized tread wear due to skidding (flat spot)
Abnormal condition of inner liner
09900-20805: Tire depth gauge
Tire tread depth (front and rear)
Service Limit: 1.6 mm
CHASSIS 5-33
5-34 CHASSIS
VALVE
Inspect the valve 1 for damage.
If the seal rubber is peeling or damaged, replace the valve with a new one.
NOTE:
If the external appearance of the valve shows no abnormal condition, removing the valve is not necessary.
Inspect the valve core seal 2 for deformation or damage.
If the valve core seal has abnormal deformation, replace the valve with a new one.
INSTALLATION
VALVE
Clean any dust or rust around the valve hole 1.
Install the valve in the rim.
NOTE:
To properly install the valve
2
into the valve hole, apply a special tire lubricant or neutral soapy liquid to the valve.
Be careful not to damage the valve lip A.
B Wheel
TIRE
Apply a special tire lubricant to the tire bead.
When installing the tire, make sure the arrow 1 faces the direction of wheel rotation and align the balancing.
Replace the removed valve with a new one.
The tire is designed to have specified rotational direction.
Never apply oil, grease, or gasoline to the tire bead.
When installing the tire, make sure that the arrow 1 faces the direction of wheel rotation and align the balancing mark 2 on the tire with the valve 3 as shown.
For installing the tire onto the wheel, refer to the instructions given by the tire changer manufacturer.
Bounce the tire several times while rotating it. This will allow the tire bead to expand outwards, making inflation easier.
NOTE:
Before inflating the tire, make sure that the balance mark is aligned with the valve stem.
CHASSIS 5-35
5-36 CHASSIS
After the tire is properly seated to the wheel rim, inflate the tire to the recommended pressure. Correct the wheel balance if necessary.
Do not inflate the tire to more than 400 kPa (4.0 kgf/ cm
2
). The tire could burst with sufficient force to cause severe injury. Never stand directly over the tire while inflating it.
When using a preset pressure air inflator, pay special care for the set pressure adjustment.
NOTE:
Check the “rim line”
1
cast on the tire side walls. The line must be equidistant from the wheel rim all the way around. If the distance between the rim line and wheel rim varies, this indicates that the bead is not properly seated. If this is so, deflate the tire completely, and unseat the bead on both sides. Then, coat the bead with lubricant, and re-seat the tire.
Adjust the tire pressure to the specification.
Do not run a repaired tire at a high speed.
Cold inflation tire pressure
Solo riding
Front : 125 kPa (1.25 kgf/cm
2
)
Rear : 175 kPa (1.75 kgf/cm
2
)
Dual riding (except for UF50Z)
Front : 125 kPa (1.25 kgf/cm
2
)
Rear : 230 kPa (2.30 kgf/cm
2
)
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
6-1
CONTENTS
CAUTIONS IN SERVICING ........................................................................................................................... 6- 2
CONNECTOR .......................................................................................................................................... 6- 2
COUPLER ................................................................................................................................................ 6- 2
CLAMPS .................................................................................................................................................. 6- 2
FUSE ........................................................................................................................................................ 6- 2
SEMICONDUCTOR EQUIPPED PARTS ................................................................................................ 6- 2
CONNECTING THE BATTERY ............................................................................................................... 6- 3
WIRING PROCEDURE ............................................................................................................................ 6- 3
USING THE MULTI CIRCUIT TESTER ................................................................................................... 6- 3
LOCATION OF ELECTRICAL COMPONENTS ........................................................................................... 6- 4
CHARGING AND LIGHTING SYSTEM ........................................................................................................ 6- 6
DESCRIPTION ......................................................................................................................................... 6- 6
TROUBLESHOOTING ............................................................................................................................. 6- 7
INSPECTION ........................................................................................................................................... 6- 8
STARTER SYSTEM ....................................................................................................................................... 6-10
DESCRIPTION ......................................................................................................................................... 6-10
TROUBLESHOOTING ............................................................................................................................. 6-10
STARTER MOTOR REMOVAL AND DISASSEMBLY ............................................................................ 6-11
STARTER MOTOR INSPECTION ........................................................................................................... 6-12
STARTER MOTOR REASSEMBLY ........................................................................................................ 6-13
STARTER RELAY INSPECTION ............................................................................................................ 6-13
IGNITION SYSTEM ....................................................................................................................................... 6-14
DESCRIPTION ......................................................................................................................................... 6-14
TROUBLESHOOTING ............................................................................................................................. 6-14
INSPECTION ........................................................................................................................................... 6-16
FUEL LEVEL INDICATOR SWITCH ............................................................................................................. 6-19
INSPECTION ........................................................................................................................................... 6-19
OIL LEVEL INDICATOR SWITCH ................................................................................................................ 6-20
INSPECTION ........................................................................................................................................... 6-20
THERMOELEMENT, CARBURETOR HEATER,
AND THERMOSWITCH ................................................................................................................................. 6-21
INSPECTION ........................................................................................................................................... 6-21
SPEEDOMETER ........................................................................................................................................... 6-23
REMOVAL AND DISASSEMBLY ............................................................................................................ 6-23
INSPECTION ........................................................................................................................................... 6-23
LAMPS ........................................................................................................................................................... 6-24
HEADLIGHT ............................................................................................................................................ 6-24
FRONT AND REAR TURN SIGNAL LIGHT ........................................................................................... 6-25
BRAKE LIGHT/TAILLIGHT ..................................................................................................................... 6-26
LICENSE PLATE LIGHT ......................................................................................................................... 6-27
RELAYS ......................................................................................................................................................... 6-28
STARTER RELAY .................................................................................................................................... 6-28
TURN SIGNAL RELAY ............................................................................................................................ 6-28
SWITCHES .................................................................................................................................................... 6-29
BATTERY ....................................................................................................................................................... 6-30
REMOVAL ................................................................................................................................................ 6-30
REMOUNTING ......................................................................................................................................... 6-30
SPECIFICATIONS ................................................................................................................................... 6-31
INITIAL CHARGING ................................................................................................................................ 6-31
SERVICING .............................................................................................................................................. 6-32
RECHARGING OPERATION .................................................................................................................. 6-32
SERVICE LIFE ......................................................................................................................................... 6-33
6
6-2 ELECTRICAL SYSTEM
CAUTIONS IN SERVICING
CONNECTOR
When disconnecting a connector, be sure to hold the terminals; do not pull the lead wires.
When connecting a connector, push it in so it is firmly attached.
Inspect the connector for corrosion, contamination and any breakage in the cover.
COUPLER
With a lock-type coupler, be sure to release the lock before disconnecting it. When connecting a coupler, push it in until the lock clicks shut.
When disconnecting a coupler, be sure to hold the coupler; do not pull the lead wires.
Inspect each terminal on the coupler for looseness or bends.
Inspect each terminal for corrosion and contamination.
CLAMPS
Refer to the “WIRE HARNESS, CABLE, AND HOSE ROUTING” section for proper clamping procedures. ( 7-10 to 7-16)
Bend the clamp properly, as shown in the illustration.
When clamping the wire harness, do not allow it to hang down.
Do not use wire or any other substitutes for the band-type clamp.
FUSE
When a fuse blows, always investigate the cause, correct the problem, and then replace the fuse.
Do not use a fuse of a different capacity.
Do not use any substitutes for the fuse (e.g., wire).
Click
CORRECT INCORRECT
SEMICONDUCTOR EQUIPPED PARTS
Do not drop any part that contains a semiconductor (e.g., CDI unit, regulator/rectifier).
When inspecting the part, follow the inspection instructions carefully. Neglecting proper procedures may cause this part to be damaged.
CONNECTING THE BATTERY
When disconnecting terminals from the battery for disassembly or servicing, be sure to disconnect the - battery lead wire, first.
When connecting the battery lead wires, be sure to connect the + battery lead wire, first.
If the terminal is corroded, remove the battery, pour warm water over it and clean it with a wire brush.
After connecting the battery, apply a light coat of grease to the battery terminals.
Install the cover over the + battery terminal.
ELECTRICAL SYSTEM 6-3
WIRING PROCEDURE
Properly route the wire harness according to the “WIRE HAR-
NESS, CABLE, AND HOSE ROUTING”. ( 7-10 to 7-16)
USING THE MULTI CIRCUIT TESTER
Properly use the multi circuit tester + and - probes. Improper use can cause damage to the motorcycle and tester.
If the voltage and current values are not known, begin measuring in the highest range.
When measuring the resistance, make sure that no voltage is applied. If voltage is applied, the tester will be damaged.
After using the tester, be sure to turn the switch to the OFF position.
Before using the multi circuit tester, read its instruction manual.
6-4 ELECTRICAL SYSTEM
LOCATION OF ELECTRICAL COMPONENTS
4
2
3
1
5
1 Fuel level indicator switch
2 Thermoswitch
3 Oil level indicator switch
4 CDI unit
5 Right handlebar switch
6 Horn
7 Turn signal relay
8 Resistor
9 Regulator/rectifier
0 Generator
A Starter motor
A
0
7
8
9
6
B
ELECTRICAL SYSTEM 6-5
C
D
E
I
B Left handlebar switch
C Ignition switch
D Thermoelement
E Carburetor heater
F Battery
G Fuse
H Starter relay
I Ignition coil
H
F
G
6-6 ELECTRICAL SYSTEM
CHARGING AND LIGHTING SYSTEM
DESCRIPTION
The charging system for this motorcycle uses a generator, as shown below. The charging and lighting coils are mounted on the generator stator and generate AC current as the generator rotor turns. The AC current, which is generated in the charging coil, is converted by the regulator/rectifier into DC current. The DC current then charges the battery and the lighting coil uses the regulated AC current to supply the meter light, headlight, and license plate light.
W/R
Y/W
Generator
Y/W Y/W
Lighting switch
Regulator/rectifier
R
B/W
Fuse
Battery
Headlight Meter light Taillight License plate light
ELECTRICAL SYSTEM 6-7
TROUBLESHOOTING
Battery runs down quickly.
Check accessories which use excessive amounts of electricity.
No accessories
Check the battery for current leakage.
( 6-8)
No current leaks
Measure the charging voltage between the battery terminals.
( 6-8)
Incorrect
Check the continuity of the startor coil.
( 6-9)
Continuity
Accessories are installed
Current leaks
Correct
No continuity
• Remove accessories
• Short circuit of the wire
harness
• Loose or disconnected
wires
• Faulty battery
• Faulty battery
• Abnormal driving
condition
• Faulty stator coil or
disconnected lead
wires
Inspect the regulator/rectifier.
( 6-9)
Correct
Incorrect
• Faulty regulator
/rectifier
Others
Inspect the wires.
Battery overcharges
Correct
Incorrect
• Short circuit of wire
harness
• Improper coupler
contact
• Faulty battery
• Faulty regulator/rectifier
• Faulty battery
• Poor contact of generator lead wire coupler
6-8 ELECTRICAL SYSTEM
INSPECTION
BATTERY CURRENT LEAKAGE
Turn the ignition switch to the “OFF” position.
Remove the battery holder cover. (
Disconnect the - battery lead wire.
6-30)
Measure the battery current between the - battery terminal and the - battery lead wire using the multi circuit tester. If the reading exceeds the specified value, leakage is evident.
09900-25008: Multi circuit tester set
Tester knob indication: Current ( , 20 mA)
Battery current (leak): Under 1 mA
Because the current leak might be large, turn the multi circuit tester to the high range, first to avoid damage to the tester.
Do not turn the ignition switch to the “ON” position when measuring the current.
When checking to find the excessive current leakage, remove the couplers and connectors, one by one, checking each part.
CHARGING OUTPUT
Remove the battery holder cover. ( 6-30)
Start the engine, turn the lighting switch to the on ( ) position and run the engine at 5 000 r/min.
Measure the DC voltage between the + and - battery termi-
( nals using the multi circuit tester. If the voltage is not within the specified value, inspect the stator coil and regulator/rectifier.
6-9)
NOTE:
When performing this measurement, make sure that the battery is fully charged.
09900-25008: Multi circuit tester set
Tester knob indication: Voltage ( )
Charging output (regulated voltage)
Standard: 13.5 – 15.0 V at 5 000 r/min
Battery
(DC V)
Tester
STATOR COIL RESISTANCE
Remove the trunk. ( 5-4)
Disconnect the generator coupler 1.
Measure the resistance between the lead wires using the multi circuit tester. If the resistance is not within the specified value, replace the stator coil with a new one.
09900-25008: Multi circuit tester set
Tester knob indication: Resistance (
Ω
Stator coil resistance
Standard: 0.5 – 2.0
Ω
0.3 – 1.5
Ω
1
ELECTRICAL SYSTEM 6-9
W/R
Ω
Y/W
Ω
REGULATOR/RECTIFIER
Remove the front leg shield. ( 5-3)
Disconnect the regulator/rectifier coupler 1.
Measure the voltage between the terminals using the multi circuit tester, as indicated in the table below. If voltage is not within the specified value, replace the regulator/rectifier with a new one.
09900-25008: Multi circuit tester set
Tester knob indication: Diode test ( )
Unit: V
A
B
C
D
A
0.5 – 1.4
1.4 – 1.5
1.4 – 1.5
+ Tester probe
B
1.4 – 1.5
1.4 – 1.5
1.4 – 1.5
C
1.4 – 1.5
1.4 – 1.5
0.6 – 1.5
D
1.4 – 1.5
1.4 – 1.5
0.6 – 1.5
NOTE:
If the tester reads under 1.4 V, disconnect the tester probes from the wire leads, and then replace the multi circuit tester’s battery.
D
C
1
A
B
6-10 ELECTRICAL SYSTEM
STARTER SYSTEM
DESCRIPTION
The starter system consists of the following components: the starter motor, starter relay, starter button, brake light switches (front and rear brakes), ignition switch, and battery. Pressing the starter button, while squeezing the front or rear brake lever, energizes the starter relay, causing the contact points to close, thus, completing the circuit from the starter motor to the battery.
R/W
R/W
Starter motor
Starter relay
Y/G
B/W
Starter button
R
W
Front brake light switch
W O O
Ignition switch
R
Fuse
R
W
Rear brake light switch
O
Battery
B/W
TROUBLESHOOTING
Starter motor will not run.
Turn the ignition switch to the “ON” position.
Grasp the front or rear brake lever. Listen for a click from the starter relay when the starter button is pushed.
Clicks
No click
Continued on next page
Check if the starter motor runs when its terminal is connected to the battery terminal (Do not use a thin wire because a large amount of current flows.)
Runs Does not run
• Faulty starter motor
• Faulty starter relay
• Loose or disconnected starter
motor lead wire
ELECTRICAL SYSTEM 6-11
Measure the starter relay voltage at the starter relay connectors (between W and Y/G ) when the starter button is pushed.
No voltage
Voltage
• Faulty ignition switch
• Faulty starter button
• Faulty brake light switches
(front and rear brakes)
• Improper connector contact
• Open circuit in wire harness
Inspect the starter relay.
( 6-13)
Correct
Incorrect
Others
Engine does not turn though the starter motor runs.
• Faulty starter pinion
gear assembly
• Faulty starter relay
• Improper starter relay contact
STARTER MOTOR REMOVAL AND
DISASSEMBLY
Disconnect the starter motor lead wire and remove the starter motor 1.
1
6-12 ELECTRICAL SYSTEM
Disassemble the starter motor, as shown.
STARTER MOTOR INSPECTION
CARBON BRUSHES
Inspect the carbon brushes for abnormal wear, cracks, or smoothness in the brush holder. If any damages are found, replace the brush assembly with a new one.
COMMUTATOR
Inspect the commutator for discoloration, abnormal wear, or undercut A. If any damages are found, replace the armature with a new one.
If the commutator surface is discolored, polish it with #400 sandpaper and wipe it using a clean, dry cloth.
If there is no undercut, scrape out the insulator 1 with a saw blade.
ARMATURE COIL
Check for continuity between each segment and the armature shaft using the multi circuit tester. If there is no continuity between the segments or there is continuity between the segments and shaft, replace the armature with a new one.
09900-25008: Multi circuit tester set
Tester knob indication: Continuity test ( )
ELECTRICAL SYSTEM 6-13
STARTER MOTOR REASSEMBLY
Reassemble the starter motor in the reverse order of disassembly. Pay attention to the following point:
Apply a small quantity of SUZUKI MOLY PASTE to the armature shaft.
99000-25140: SUZUKI MOLY PASTE
STARTER RELAY INSPECTION
Remove the battery holder cover. (
Remove the starter relay.
6-30)
Apply 12 volts to terminals A and B, and measure for continuity between terminals C and D as shown. If the starter relay clicks and continuity is found, the relay is operating correctly.
09900-25008: Multi circuit tester set
Tester knob indication: Continuity test ( )
Measure the starter relay resistance between the terminals using the multi circuit tester. If the resistance is not within the specified value, replace the starter relay with a new one.
09900-25008: Multi circuit tester set
Tester knob indication: Resistance (
Ω
Starter relay resistance
Standard: 50 – 90
Ω
C A
D
B
6-14 ELECTRICAL SYSTEM
IGNITION SYSTEM
DESCRIPTION
In the capacitor discharged ignition system, the battery’s electrical energy charges the capacitor. This energy is released in a single surge at the specified ignition timing point and the current flows through the primary side of the ignition coil. A high voltage is induced in the secondary windings of the ignition coil, resulting in a strong spark between the spark plug gap.
R
Battery
B/W
Regulator/ rectifier
Y/W
W/R
R
Br
W
O
CDI unit
W/Bl
Ignition coil
Spark
Plug
B/W
B/W
Generator
TROUBLESHOOTING
No spark or poor spark
Check the ignition system couplers for poor connections.
Correct
Measure the battery voltage between input lead wires (O and B/W) at the CDI unit with the ignition switch in the “ON” position.
Correct
Continued on next page
B/W
Looseness • Improper coupler
connection
Incorrect • Faulty ignition switch
• Broken wire harness or
poor connection of related
circuit couplers
ELECTRICAL SYSTEM 6-15
Measure the ignition coil primary peak voltage. ( 6-16)
NOTE: The ignition coil peak voltage inspection method is applicable only with the multi circuit tester and the peak volt adaptor.
Correct
Inspect the ignition coil. ( 6-17)
Correct
Measure the pickup coil peak voltage and resistance. ( 6-17 and 6-18)
NOTE: The pickup coil peak voltage inspection is applicable only with the multi circuit tester and the peak volt adaptor.
Incorrect
Correct
Correct
Inspect the spark plug.
( 2-5 and 2-6)
Correct
• Faulty CDI unit
Incorrect
• Faulty spark plug
Incorrect
• Improper spark plug
connection
• Faulty ignition coil
• Faulty pickup coil
• Open circuit in wiring
harness
• Improper ignition coupler
connection
6-16 ELECTRICAL SYSTEM
INSPECTION
IGNITION COIL PRIMARY PEAK VOLTAGE
Remove the left side leg shield. ( 5-3)
Remove the spark plug cap and spark plug.
Connect a new spark plug to the spark plug cap and ground it to the crankcase.
NOTE:
Make sure that the spark plug cap and spark plug are connected properly.
Measure ignition coil primary peak voltage using the multi circuit tester in the following procedure.
Connect the multi circuit tester with the peak voltage adaptor as follows.
Ignition coil:
Ground (+ probe) – White/Blue terminal (- probe)
NOTE:
Do not disconnect the ignition coil coupler.
09900-25008: Multi circuit tester set
Before using the multi circuit tester and peak volt adaptor, be sure to refer to the appropriate instruction manual.
Turn the ignition switch to the “ON” position.
Pull the brake lever.
Press the starter button and allow the engine to crank for a few seconds, and then measure the ignition coil primary peak voltage.
Repeat the above procedure a few times and measure the highest ignition coil primary peak voltage.
Tester knob indication: Voltage ( )
Ignition coil primary peak voltage: More than 150 V
CDI unit
Battery
W/Bl
New spark plug
Peak volt adaptor
While testing, do not touch the tester probes and spark plug to prevent receiving an electric shock.
If the voltage is lower than the specified values, inspect the ignition coil. ( 6-17)
IGNITION COIL RESISTANCE
Remove the footboard. ( 5-3)
Disconnect the ignition coil coupler 1.
Measure the ignition coil resistance in both the primary and secondary windings using the multi circuit tester. If the resistance in both the primary and secondary windings is close to the specified values, the windings are in sound condition.
09900-25008: Multi circuit tester set
Tester knob indication: Resistance (
Ω
Ignition coil resistance
Primary: 0.2 – 1.5
Ω
Secondary: 10 – 20 k
Ω
ELECTRICAL SYSTEM 6-17
1
PICKUP COIL PEAK VOLTAGE
Remove the trunk. ( 5-4)
NOTE:
Make sure that all of the couplers are connected properly and the battery is fully charged.
Disconnect the CDI unit coil coupler 1.
Measure the pickup coil peak voltage in the following procedure.
Connect the multi circuit tester with the peak volt adaptor as follows.
Brown (- Probe) – White (+ Probe)
09900-25008: Multi circuit tester set
Before using the multi circuit tester and peak volt adaptor, be sure to read the appropriate instruction manual.
Turn the ignition switch to the “ON” position.
Measure the pickup coil peak voltage while squeezing the front or rear brake lever and pressing the starter button to turn the engine for a few seconds.
Repeat the above procedure a few times and measure the highest pickup coil peak voltage.
Tester knob indication: Voltage ( )
Pickup coil peak voltage: More than 5.0 V
If the peak voltage measured on the CDI unit coupler is lower than the standard value, measure the peak voltage on the pickup coil coupler as follows.
1
Y/W
W/R
W
Br
W
Br
+
-
Peak volt adaptor
Gererator
6-18 ELECTRICAL SYSTEM
Remove the trunk. ( 5-4)
Disconnect the generator coupler 1.
Connect the multi circuit tester with the peak volt adaptor as follows.
Brown (- Probe) – White (+ Probe)
Measure the pickup coil peak voltage in the same manner as on the CDI unit coupler.
09900-25008: Multi circuit tester set
Tester knob indication: Voltage ( )
Pickup coil peak voltage: More than 5.0 V
If the peak voltage on the generator coupler is within specification, but on the CDI unit coupler is not within specification, replace the wire harness with a new one. If both peak voltages are out of specification, replace the pickup coil with a new one.
1
Gererator
Y/W
W/R
W
Br
+
-
Peak volt adaptor
PICKUP COIL RESISTANCE
Remove the trunk. ( 5-4)
Disconnect the generator coupler 1.
Measure the resistance between the lead wires using the multi circuit tester. If the resistance is not within the specified value, the pickup coil must be replaced.
09900-25008: Multi circuit tester set
Tester knob indication: Resistance (
Ω
Pickup coil resistance: 120 – 250
Ω
1
FUEL LEVEL INDICATOR SWITCH
Fuse
Ignition switch
Fuel level indicator light
ELECTRICAL SYSTEM 6-19
Battery
Fuel level indicator switch
INSPECTION
Remove the trunk. ( 5-4)
Turn the ignition switch to the “ON” position, and disconnect the fuel level indicator coupler 1 going into the fuel level indicator switch, connect the lead wires from the main wiring harness with a jumper lead and check whether the fuel level indicator light comes on. If the fuel level indicator light comes on, the circuit of the fuel level indicator light is in good condition. If the fuel level indicator light does not come on, replace the indicator bulb or repair the circuit connection. If the bulb is in good condition, the fuel level indicator switch may be faulty.
1
Main wiring harness
From fuel tank
Jumper lead
Inspect the fuel indicator switch for any faults. If any faults are found, replace the fuel indicator switch with a new one.
Remove the fuel level indicator switch 2 from the fuel tank.
2
6-20 ELECTRICAL SYSTEM
Connect a 12 V battery to the fuel level indicator switch and ground it through a 2 W bulb. The bulb should light up after several seconds if the switch is in good condition.
When the switch is immersed in water under the above condition, the bulb should go out. If the bulb remains lit, replace the fuel level indicator switch.
12 V Battery
Test bulb
12 V 2 W
OIL LEVEL INDICATOR SWITCH
INSPECTION
Remove the trunk. ( 5-4)
Disconnect the oil level indicator switch coupler and remove the oil level indicator switch 1.
Measure the continuity between the lead wires of the oil level indicator switch.
If there is no continuity between the lead wires when the oil level indicator switch is in the low-level position, file the contact surface or replace the oil level indicator switch with a new one.
09900-25008: Multi circuit tester set
Tester knob indication: Continuity test ( )
12 V Battery
Water
1
Test bulb
12 V 2 W
ELECTRICAL SYSTEM 6-21
THERMOELEMENT, CARBURETOR HEATER, AND THERMOSWITCH
Resistor
B/W
R
B/Y
Y/W
B/W
R Y/W
B/W
W/R Y/W
R
B/W
Y/W W/R
Y/W W/R
Y/W
Y Y
Y/W
Y/W
Thermoelement
Regulator/ rectifier
Thermoswitch
Carburetor heater
Generator
INSPECTION
THERMOELEMENT
Remove the trunk. ( 5-4)
Disconnect the thermoelement coupler 1 and remove the thermoelement 2.
Connect the thermoelement lead wires to a 12 V battery.
Wait five minutes and feel the thermoelement to see if it has reached approximately 36°C. If the appropriate temperature is not reached, replace the thermoelement with a new one.
NOTE:
This check should be carried out when the engine is cold.
1
2
6-22 ELECTRICAL SYSTEM
CARBURETOR HEATER
Remove the trunk. ( 5-4)
Disconnect the carburetor heater lead wire and remove the carburetor heater 1.
Measure the resistance between the terminals using the multi circuit tester. If the resistance is not within the specified value, replace the carburetor heater with a new one.
09900-25008: Multi circuit tester set
Tester knob indication: Resistance (
Ω
Standard resistance: 8 – 18
Ω
NOTE:
This check should be carried out when the engine is cold.
THERMOSWITCH
Remove the upper fuel tank cover. ( 5-5)
Disconnect the thermoswitch coupler and remove the thermoswitch 1.
The temperature at which the thermoswitch closes must be within specification. Measure the closing temperature of the thermoswitch as follows.
Connect the thermoswitch to the multi circuit tester and place it in a container of water. Cool the water with ice 2 and observe the temperature when the thermoswitch closes.
09900-25008: Multi circuit tester set
Tester knob indication: Continuity test ( )
Thermoswitch specification:
OFF
→
ON
→
1
1
SPEEDOMETER
REMOVAL AND DISASSEMBLY
Remove the speedometer assembly. ( 5-23)
Disassemble the speedometer, as shown.
ELECTRICAL SYSTEM 6-23
INSPECTION
Check the continuity between the lead wires using the multi circuit tester. If there is no continuity, replace the respective parts.
09900-25008: Multi circuit tester set
Tester knob indication: Continuity test ( )
6-24 ELECTRICAL SYSTEM
LAMPS
HEADLIGHT
Headlight bulb: 12 V 35/35 W
HEADLIGHT BULB REPLACEMENT
Remove the front leg shield. ( 5-3)
Remove the headlight bulb.
If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.
FRONT AND REAR TURN SIGNAL LIGHT
ELECTRICAL SYSTEM 6-25
Turn signal light: 12 V 10 W
FRONT AND REAR TURN SIGNAL LIGHT BULB
REPLACEMENT
Remove the front turn signal light lens 1 and rear turn signal light lens 2.
1
Remove the front turn signal light bulb 3 and rear turn signal light bulb 4.
If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.
3
2
4
6-26 ELECTRICAL SYSTEM
BRAKE LIGHT/TAILLIGHT
Brake light/taillight: 12 V 21/5 W
BRAKE LIGHT/TAILLIGHT BULB REPLACEMENT
Remove the brake light/taillight lens.
Remove the brake light/taillight bulb.
If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.
LICENSE PLATE LIGHT
ELECTRICAL SYSTEM 6-27
License plate light: 12 V 5 W
LICENSE PLATE LIGHT BULB REPLACEMENT
Remove the license plate light case mounting screw.
Remove the license plate light case.
Remove the license plate light bulb.
If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.
6-28 ELECTRICAL SYSTEM
RELAYS
STARTER RELAY
(
The starter relay is located behind the battery holder cover.
6-30)
TURN SIGNAL RELAY
(
The turn signal relay is located behind the front leg shield.
5-3)
If the turn signal light does not light, inspect the bulb or repair the circuit connection.
If the bulb and circuit connection are OK, the turn signal relay may be faulty, replace it with a new one.
NOTE:
When making this test, make sure that the battery is fully charged.
ELECTRICAL SYSTEM 6-29
SWITCHES
Measure each switch for continuity using the multi circuit tester. If there is no continuity, replace the respective switch with a new one.
IGNITION SWITCH
Position
Color
ON ( )
B/R
C ( • )
OFF ( )
Lock ( )
B/W Bl/W
LIGHTING SWITCH
Position
Color
ON ( )
G/W
OFF ( • )
Gr
TURN SIGNAL LIGHT SWITCH
Position
Color
L ( )
B Lbl
•
R ( )
STARTER BUTTON
Position
Color
•
B/W
PUSH
DIMMER SWITCH
Position
Color
HI
Gr
LO
Y
O
Y/G
Y/W
Lg
W
R
HORN BUTTON
Position
Color
PUSH
•
G
FRONT BRAKE LIGHT SWITCH
Position
Color
ON
O
OFF
REAR BRAKE LIGHT SWITCH
Position
Color
ON
O
OFF
WIRE COLOR
B : Black
Br : Brown
G : Green
Gr : Gray
Lbl : Light blue W : White
Lg : Light green
O : Orange
R : Red
B/R : Black with Red tracer
B/W : Black with White tracer
Bl/W : Blue with White tracer
G/W : Green with White tracer
Y/G : Yellow with Green tracer
Y/W : Yellow with White tracer
B/W
W
W
6-30 ELECTRICAL SYSTEM
BATTERY
REMOVAL
Remove the battery holder cover 1.
Remove the battery.
NOTE:
Disconnect the
-
battery lead wire, first.
REMOUNTING
Remount the battery in the reverse order of removal.
1
SPECIFICATIONS
Type designation
Capacity
Standard electrolyte
(Specific gravity)
CB4L-B, FB4L-B
12 V, 14.4 kC (4 Ah)/10 HR
1.280 at 20°C
When installing the battery onto the motorcycle, connect the breather tube to the battery vent.
INITIAL CHARGING
FILLING ELECTROLYTE
Remove the short sealed tube.
Fill the battery with electrolyte to the UPPER LEVEL line 1.
Wait approximately a half-hour and check the electrolyte level.
If the electrolyte level has fallen, add electrolyte to the UPPER
LEVEL line 1.
Slowly charge the battery with a battery charger at the specified current, as described below.
Maximum charging current: 0.4 A
The charging time for a new battery is determined by the number of months that have elapsed since the date of manufacture.
The manufacture’s date is indicated by the six-digit stamp 2 located on the battery. The day, month and year are each indicated by two digits.
Months after manufacturing
Within 6
Within 9
Within 12
Over 12
Necessary charging hours
20
30
40
60
NOTE:
If necessary, add only distilled water to the UPPER LEVEL line.
Install the seal caps after charging.
After charging the battery, allow the battery to cool for two hours, before installing it.
ELECTRICAL SYSTEM 6-31
6-32 ELECTRICAL SYSTEM
SERVICING
Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, clean the battery terminals with sandpaper.
Check the electrolyte level, and if necessary, add distilled water to raise the electrolyte level, for each cell, to the UPPER LEVEL line.
Use a hydrometer to measure the electrolyte specific gravity reading. If the reading is 1.22 or less, as corrected to 20°C, this indicates that the battery needs to be charged.
Specific gravity at 20°C
1.250 – 1.280
1.220 – 1.250
Below 1.220
Condition
Normal
Under charged
Run down
09900-28403: Hydrometer
Measure
Charge
Charge or replace
RECHARGING OPERATION
NOTE:
When charging the battery, be sure to remove the battery from the motorcycle to protect the regulator/rectifier against excessive voltage.
Use the following formula to correct the specific gravity reading to 20°C.
S20 = St + 0.0007 (t-20)
Where S20 = corrected value of specific gravity
(20°C)
St = value of specific gravity read at temperature t°C
0.0007 = temperature coefficient of specific gravity t = temperature in degrees centigrade at which St was read.
Check the corrected specific gravity reading with the chart, to determine the charging time in hours. This is when a constant-current charge at a rate of 0.4 amperes (which is a tenth of the capacity of the present battery) is used.
When charging the battery, do not allow the electrolyte temperature to exceed 45°C. Interrupt the operation, as necessary, to let the electrolyte cool down.
Electrolyte specific gravity: 1.280 at 20°C
Do not quick charge the battery. Quick charging will shorten the life of the battery.
Charging time (hour)
Normal
Recharge
Recharge or replace
Temperature
SERVICE LIFE
Lead oxide is on the plates of the battery and will gradually come off of the plates during the life of the battery. When the bottom of the battery case becomes full of this sediment, replace the battery. If the battery is not charged for a long period of time, lead sulfate may accumulate on the surface of the plates. If this occurs, replace the battery with a new one.
STORAGE
When a battery is not used for a long period of time, sulfation may occur. When the motorcycle is not used for more than one month (especially during the winter season), the battery should be charged at least once a month.
Before charging the battery, remove the seal cap from each cell.
Keep fire and sparks away from a battery which is being charged.
When removing the battery from the motorcycle, be
sure to remove the - battery terminal, first.
ELECTRICAL SYSTEM 6-33
SERVICING INFORMATION
SERVICING INFORMATION
7-1
CONTENTS
TROUBLESHOOTING ...................................................................................... 7- 2
ENGINE ........................................................................................................ 7- 2
CARBURETOR ............................................................................................ 7- 4
CHASSIS ...................................................................................................... 7- 5
BRAKES ....................................................................................................... 7- 6
ELECTRICAL ............................................................................................... 7- 7
BATTERY ...................................................................................................... 7- 8
WIRING DIAGRAM ........................................................................................... 7- 9
WIRE HARNESS, CABLE, AND HOSE ROUTING ......................................... 7-10
WIRE HARNESS .......................................................................................... 7-10
CABLE ROUTING ........................................................................................ 7-12
FUEL SYSTEM HOSE ROUTING ................................................................ 7-14
BATTERY BREATHER HOSE ROUTING .................................................... 7-15
FRONT BRAKE HOSE ROUTING ............................................................... 7-16
SPECIAL TOOLS .............................................................................................. 7-17
TIGHTENING TORQUE .................................................................................... 7-19
ENGINE ........................................................................................................ 7-19
CHASSIS ...................................................................................................... 7-19
TIGHTENING TORQUE CHART .................................................................. 7-20
SERVICE DATA ................................................................................................ 7-21
7
7-2 SERVICING INFORMATION
TROUBLESHOOTING
ENGINE
Complaint
Engine will not start or is hard to start.
Symptom and possible causes
Compression too low
1. Worn cylinder.
2. Worn piston ring.
3. Gas leaks from the joint in crankcase, cylinder or cylinder head.
4. Damaged reed valve.
5. Loose spark plug.
6. Broken, cracked or damaged piston.
Spark plug not sparking
1. Damaged spark plug.
2. Damaged spark plug cap.
3. Fouled spark plug.
4. Wet spark plug.
5. Defective ignition coil.
6. Defective stator coil.
7. Open or short in high-tension cord.
8. Defective ignition switch.
No fuel reaching the carburetor
1. Clogged hole in the fuel tank cap.
2. Clogged or defective fuel valve.
3. Defective needle valve.
Remedy
Replace.
Repair or replace.
Repair or replace.
Replace.
Tighten.
Replace.
Replace.
Replace.
Clean or replace.
Clean and dry or replace.
Replace.
Replace.
Replace.
Replace.
Engine stalls easily.
Clean or replace.
Clean or replace.
Replace with needle valve seat.
Clean or replace.
Clean or replace.
Replace.
Clean.
Clean.
Clean.
Engine is noisy.
Clutch slips.
4. Clogged fuel hose or defective vacuum hose.
1. Fouled spark plug.
2. Defective CDI unit.
3. Clogged fuel hose.
4. Clogged carburetor jet.
5. Clogged exhaust pipe.
Noise appears to come from piston
1. Worn down piston.
2. Worn cylinder.
3. Carbon built-up in the combustion chamber.
4. Worn piston pin, bearing or piston pin bore.
5. Worn piston rings or ring grooves.
Noise seems to come from crankshaft
1. Worn or burnt crankshaft bearings.
2. Worn or burnt big-end bearing.
Noise seems to come from final gearbox
1. Worn or rubbing final gears.
2. Worn splines.
3. Worn or damaged bearings of driveshaft or rear axle shaft.
1. Worn or damaged clutch shoes.
2. Worn clutch drum.
Replace.
Replace.
Clean.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
SERVICING INFORMATION 7-3
Complaint
Engine idles poorly.
Engine runs poorly in high-speed range.
Dirty or heavy exhaust smoke.
Engine lacks power.
Symptom and possible causes
1. Worn cylinder.
2. Worn piston rings.
3. Stiff piston ring.
4. Gas leaks from crankshaft oil seal.
5. Excessive spark plug gap.
6. Defective ignition coil.
7. Defective CDI unit.
8. Defective stator coil.
9. Incorrect float chamber fuel level.
10. Clogged carburetor jet.
11. Broken or damaged reed valve.
1. Worn cylinder.
2. Worn piston rings.
3. Stiff piston ring.
4. Insufficient spark plug gap.
5. Ignition not advanced sufficiently due to poorly working ignition coil.
6. Defective CDI unit.
7. Defective stator coil.
8. Low float chamber fuel level.
9. Dirty air cleaner element.
10. Clogged fuel hose, resulting in inadequate fuel supply to the carburetor.
11. Clogged fuel valve vacuum pipe.
1. Incorrect engine oil.
Remedy
Replace.
Replace.
Replace.
Replace.
Adjust or replace.
Replace.
Replace.
Replace.
Adjust float height.
Clean.
Replace.
Replace.
Replace.
Replace.
Regap or replace.
Replace.
Replace.
Replace.
Adjust float height.
Clean.
Clean and prime.
Clean.
Change.
Engine overheats.
1. Worn cylinder.
2. Worn piston rings.
3. Stiff piston rings.
4. Gas leaks from crankshaft oil seal.
5. Insufficient spark plug gap.
6. Clogged carburetor jet.
7. Incorrect float chamber fuel level.
8. Clogged air cleaner element.
9. Fouled spark plug.
10. Air leakage from intake pipe.
11. Slipping or worn drive belt.
12. Damaged or worn rollers in the movable drive face.
13. Weakened movable drive face spring.
14. Rich air-fuel mixture due to defective starter system.
1. Carbon build-up on piston crown.
2. Defective oil pump or clogged oil circuit.
3. Low float chamber fuel level.
4. Air leakage from intake pipe.
5. Incorrect engine oil.
6. Incorrect spark plug.
7. Clogged exhaust pipe/muffler.
Replace.
Replace.
Replace.
Replace.
Regap or replace.
Clean.
Adjust float height.
Clean.
Clean or replace.
Tighten or replace.
Replace.
Replace.
Replace.
Replace.
Clean.
Clean or replace.
Adjust float height.
Tighten or replace.
Change.
Change.
Clean or replace.
7-4 SERVICING INFORMATION
CARBURETOR
Complaint
Starting difficulty.
Idling or low-speed trouble.
Medium or highspeed trouble.
Overflow and fuel level fluctuations.
Symptom and possible causes
1. Defective thermoelement.
2. Air leaking from the joint between intake pipe and carburetor.
3. Air leaking from carburetor joint or vacuum hose joint.
4. Clogged fuel pipe.
1. Clogged or loose pilot jet.
2. Air leaking from carburetor joint, vacuum pipe joint, or intake pipe.
3. Improperly operating thermoelement.
1. Clogged main jet.
2. Clogged needle jet.
3. Improperly set fuel level.
4. Improperly operating throttle valve.
5. Clogged fuel filter.
1. Worn or damaged needle valve.
2. Broken needle valve spring.
3. Improperly working float.
4. Foreign matter on the needle valve.
5. High or low fuel level.
Remedy
Replace.
Check intake pipe and carburetor for tightness, and replace gasket.
Tighten or replace the defective part.
Clean.
Check and clean.
Tighten or replace the defective part.
Replace.
Check and clean.
Check and clean.
Check and adjust float height.
Check and adjust.
Clean or replace.
Replace.
Replace.
Check and adjust.
Clean or replace with needle seat.
Adjust float height.
SERVICING INFORMATION 7-5
CHASSIS
Complaint
Steering is heavy.
Handlebar wobbles.
Front wheel wobbles.
Symptom and possible causes
1. Overtightened steering stem nut.
2. Broken bearing/race in steering stem.
3. Distorted steering stem.
4. Low tire pressure.
1. Loss of balance between right and left front suspension.
2. Distorted front axle or crooked tire.
1. Distorted wheel rim.
2. Worn front wheel bearings.
3. Defective or incorrect tire.
4. Loose front axle nut.
5. Loose bolt or nut on the rear shock absorber.
6. Worn engine mounting bushing.
7. Loose engine mounting nuts or bolts.
1. Weak springs.
Adjust.
Replace.
Replace.
Adjust.
Replace.
Replace.
Replace.
Replace.
Replace.
Tighten.
Tighten.
Replace.
Tighten.
Replace.
Remedy
Front suspension too soft.
Front suspension too noisy.
Rear wheel wobbles.
Rear suspension too soft.
Rear suspension too noisy.
1. Insufficient grease on the spring and damper.
2. Loose front suspension fastener.
1. Distorted wheel rim.
2. Defective or incorrect tire.
3. Loose rear axle nut.
4. Worn engine mounting bushing.
5. Loose engine mounting nuts or bolts.
1. Weak spring.
2. Rear shock absorber leaks oil.
1. Loose bolt or nut on the rear shock absorber.
2. Worn engine mounting bushing.
Add.
Tighten.
Replace.
Replace.
Tighten.
Replace.
Tighten.
Replace.
Replace.
Tighten.
Replace.
7-6 SERVICING INFORMATION
BRAKES
Complaint
Brake power insufficient.
Brake squeaks.
Brake lever stroke excessive.
Brake fluid leaks.
Brake drags.
Symptom and possible causes
1. Leakage of brake fluid.
2. Worn brake pads.
3. Oil on brake pad surface.
4. Worn brake disc.
5. Air in hydraulic system.
6. Worn brake shoes.
7. Oil on brake shoe surface.
8. Worn brake drum.
9. Excessive brake lever play.
1. Carbon adhesion on brake pad surface.
2. Tilted brake pad.
3. Damaged wheel bearing.
4. Worn brake pad.
5. Foreign material in brake fluid.
6. Clogged return port of master cylinder.
7. Brake shoe surface glazed.
8. Loose front axle or rear axle nut.
9. Worn brake shoes.
1. Air in hydraulic system.
2. Insufficient brake fluid.
3. Incorrect brake fluid.
4. Worn brake cam lever.
5. Worn brake shoe and/or drum.
1. Loose connection joints.
2. Cracked hose.
3. Worn piston seal.
1. Rusty parts.
2. Insufficient brake lever lubrication.
Remedy
Repair or replace.
Replace.
Clean brake disc and brake pads.
Replace.
Bleed.
Replace.
Clean brake drum and brake shoes.
Replace.
Adjust.
Clean surface with sandpaper.
Readjust brake pad position or replace.
Replace.
Replace.
Change brake fluid.
Disassemble and clean master cylinder.
Clean surface with sandpaper.
Tighten.
Replace.
Bleed.
Check level and add. Bleed any air.
Change.
Replace.
Replace.
Tighten.
Replace.
Replace.
Clean and lubricate.
Lubricate.
SERVICING INFORMATION 7-7
ELECTRICAL
Complaint
No sparking or poor sparking.
Spark plug soon becomes fouled with carbon.
Spark plug electrodes overheat or burn.
Generator does not charge.
Generator charges but charging rate is below the specifications.
Generator overcharges.
Unstable charging.
Starter switch does not work.
Symptom and possible causes
1. Defective ignition coil.
2. Defective spark plug.
3. Defective stator coil or pickup coil.
4. Defective CDI unit.
5. Loose connection of lead wire.
1. Excessively rich air-fuel mixture.
2. High idling speed.
3. Incorrect gasoline.
4. Dirty air cleaner element.
5. Incorrect spark plug (cold type).
6. Incorrect engine oil.
1. Incorrect spark plug (hot type).
2. Overheated engine.
3. Loose spark plug.
4. Excessively lean air-fuel mixture.
5. Not enough engine oil.
1. Open or short in lead wires, or loose lead connections.
2. Shorted, grounded, or open generator coil.
3. Shorted or punctured regulator/rectifier.
1. Lead wires tend to get shorted or open-circuited or loosely connected at terminal.
2. Grounded or open-circuited stator coils or generator.
3. Defective regulator/rectifier.
4. Defective battery cell.
1. Internal short-circuit in the battery.
2. Defective regulator/rectifier.
1. Lead wire insulation frayed due to vibration, resulting in intermittent shorting.
2. Internally shorted generator.
3. Defective regulator/rectifier.
1. Run down battery.
2. Defective switch contacts.
3. Brushes do not seat properly on the commutator in the starter motor.
4. Defective starter relay.
5. Defective starter pinion gear assembly.
6. Defective front or rear brake light switch circuit.
Remedy
Replace.
Replace.
Replace.
Replace.
Connect or tighten.
Adjust carburetor.
Adjust carburetor.
Change.
Clean or replace.
Change to hot type spark plug.
Replace.
Change to cold type plug.
Tune-up.
Tighten.
Adjust carburetor.
Check oil pump.
Repair, replace or tighten.
Replace.
Replace.
Repair or tighten.
Replace.
Replace.
Replace battery.
Replace battery.
Replace.
Repair or replace.
Replace.
Replace.
Recharge or replace.
Replace.
Repair or replace.
Replace.
Replace.
Repair or replace.
7-8 SERVICING INFORMATION
BATTERY
Complaint
Sulfation, acidic white powdery substance or spots on surfaces of cell plates.
Battery runs down quickly.
Reversed battery polarity.
Battery “sulfation”
Battery discharges too rapidly.
Symptom and possible causes
1. Insufficient electrolyte.
2. Cracked battery case.
3. Battery has been left in a run-down condition for a long time.
4. Foreign matter has entered the battery and has become mixed with the electrolyte.
Remedy
Add distilled water, if the battery has not been damaged and sulfation has not advanced too far, then recharge.
Replace.
Replace.
1. Incorrect charging method.
2. Battery cell plates have lost much of their active material as a result of overcharging.
3. A short-circuit condition exists within the battery to excessive accumulation of sediments caused by the high electrolyte specific gravity.
4. Low electrolyte specific gravity.
If sulfation has not advanced too far, try to restore the battery by replacing the electrolyte, recharging it fully with the battery detached from the motorcycle and then adjusting the electrolyte specific gravity.
Check the generator, regulator/rectifier and circuit connections and make necessary adjustments to obtain specified charging operation.
Replace and correct the charging system.
Replace.
5. Foreign matter has entered the battery and has become mixed with the electrolyte.
6. Old battery.
1. Improperly connected battery leads.
(i.e., - to + and + to -)
1. Incorrect charging rate. (When not in use, the battery should be checked at least once a month to avoid sulfation.)
2. Excessive or insufficient battery electrolyte or high or low specific gravity.
Recharge and adjust electrolyte specific gravity.
Replace the electrolyte, recharge the battery, and then adjust specific gravity.
Replace.
Replace the battery and be sure to connect it properly.
Replace.
3. The battery was left unused for too long in a cold climate.
1. Dirty container top and sides.
2. Impurities in the electrolyte or electrolyte specific gravity is too high.
Keep the electrolyte at the prescribed level, or adjust the specific gravity by consulting the battery manufacturer’s directions.
Replace the battery if badly sulfated.
Clean.
Change the electrolyte by consulting the batter y manufacturer’s directions.
SERVICING INFORMATION 7-9
WIRING DIAGRAM
Y/W
B/W
B/Y
Bl/W
B/W
Y/B
B/W
Y/W
Y/W
O
W/Bl
Br
W
B/W
B/W
G/W
O
W
O
Lbl
O
W
B/W
W/Bl
Bl/W
B/W
Y/W
B/W
Y
Y/W
Y/B
B/W
Bl
Bl/W
Y/B
Y
B
B/W
Gr
Y/B
O
Lg
Bl/W
B/W
Y/G
Y/W
Gr
G/W
G
B/W
Y
W
Gr
G
O
R
O
Bl
B/W
Y
B/W
B/W
R
R
R/W
R
R
W
Y/G
R/W
Br
W
W/R
Y/W
Lbl
B
Lg
Y/W
R
B/W
W/R
R/W
Br
W
W/R
Y/W
R
O
Bl/W
B/W
R/B
B/R
7-10 SERVICING INFORMATION
WIRE HARNESS, CABLE, AND HOSE ROUTING
WIRE HARNESS
1 Set the wires under the bracket seat striker and the tube frame.
SERVICING INFORMATION 7-11
7-12 SERVICING INFORMATION
CABLE ROUTING
SERVICING INFORMATION 7-13
7-14 SERVICING INFORMATION
FUEL SYSTEM HOSE ROUTING
SERVICING INFORMATION 7-15
BATTERY BREATHER HOSE ROUTING
Forward
Cushion
Forward
Battery
Slit position
Breather hose
NOTE:
The slit on the breather hose must face battery side.
7-16 SERVICING INFORMATION
FRONT BRAKE HOSE ROUTING
˚
14
˚
5
˚
5
SERVICING INFORMATION 7-17
SPECIAL TOOLS
09900-00401
Hexagon wrench set
09900-06107
Snap ring pliers
09900-06108
Snap ring pliers
09900-09003
Impact driver set
09900-20101
Vernier calipers
(150 mm)
09900-20202
Micrometer
(25 – 50 mm)
09900-20205
Micrometer
(0 – 25 mm)
09900-20508
Cylinder bore gauge set
09900-20605
Dial calipers
09900-20606
Dial gauge
(1/100 mm)
09900-20701
Magnetic stand
09900-20803
Thickness gauge
09900-20804
Thickness gauge
09900-20805
Tire depth gauge
09900-21304
V-block (100 mm)
09900-21602
CCI oil gauge
09900-25008
Multi circuit tester set
09900-28403
Hydrometer
09910-20116
Conrod holder
09910-32812
Crankshaft installer
09910-60611
Universal clamp wrench
09913-50121
Oil seal remover
09913-70210
Bearing installer set
09920-13120
Crankcase separating tool
09921-20210
Bearing remover
7-18 SERVICING INFORMATION
09921-20220
Bearing remover set
09923-73210
Bearing remover
09923-74510
Bearing remover
09924-84521
Bearing installer set
09930-30102
Sliding hammer
09930-40113
Rotor holder
09930-40131
Rotor holder attachment
09940-52860
Front fork oil seal installer
09941-34513
Steering inner race installer
09941-50111
Bearing remover
09941-74910
Bearing installer
09943-88211
Bearing remover/ installer
TIGHTENING TORQUE
ENGINE
ITEM
Cylinder head nut
Spark plug
Exhaust pipe mounting nut and bolt
Engine mounting bracket nut
Engine mounting nut
Clutch housing nut
Kick starter nut
Generator rotor nut
Clutch shoe nut
Kick starter lever bolt
Final gear oil drain bolt
Final gear oil level bolt
Oil pump mounting screw
CHASSIS
ITEM
Steering stem locknut
Handlebar clamp nut
Handlebar set bolt
Front brake caliper mounting bolt
Front brake hose union bolt
Front brake caliper air bleeder valve
Front brake caliper housing bolt
Front brake disc bolt
Front brake master cylinder bolt
Front axle nut
Rear axle nut
Rear shock absorber bolt (upper)
Rear shock absorber nut (lower)
Rear brake cam lever nut
SERVICING INFORMATION 7-19
120
29
35
10
32
23
10
42
N·m
30
50
25
26
23
7.5
50
40
50
10
5.5
12
4
N·m
10
28
10
65
60
50
3.2
2.3
1.0
4.2
12.0
2.9
3.5
1.0
kgf-m
3.0
5.0
2.5
2.6
2.3
0.75
5.0
4.0
5.0
1.0
0.55
1.2
0.4
kgf-m
1.0
2.8
1.0
6.5
6.0
5.0
7-20 SERVICING INFORMATION
TIGHTENING TORQUE CHART
For other nuts and bolts not listed in the preceding page, refer to this chart:
Bolt Diameter
A (mm)
Conventional or “4” marked bolt
N·m kgf-m N·m
“7” marked bolt kgf-m
4
5
1.5
3
0.15
0.3
2.3
4.5
0.23
0.45
6
8
10
12
5.5
13
29
45
0.55
1.3
2.9
4.5
10
23
50
85
1.0
2.3
5.0
8.5
14
16
18
65
105
160
6.5
10.5
16.0
135
210
240
13.5
21.0
24.0
Conventional bolt “4” marked bolt “7” marked bolt
SERVICING INFORMATION 7-21
SERVICE DATA
CYLINDER + PISTON + PISTON RING
ITEM
Piston to cylinder clearance
Cylinder bore
Piston diameter
Cylinder distortion
Cylinder head distortion
Piston ring free end gap
Piston ring end gap
Piston-ring-to-piston-ring-groove clearance
Piston pin bore
Piston pin O.D.
STANDARD
0.06 – 0.07
41.005 – 41.020
Measure at 20 mm from the top surface
40.940 – 40.955
Measure at 15 mm from the skirt end
—
—
1st
2nd
R
R
R
Approximately 4.0
Approximately 4.3
0.10 – 0.25
1st & 2nd
1st
2nd
0.03 – 0.07
0.02 – 0.06
10.002 – 10.010
9.995 – 10.000
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod deflection
Crank web to web width
Crankshaft runout
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pump discharge rate
STANDARD
14.003 – 14.011
—
36.0 ± 0.05
—
SPECIFICATION
30.000 (30/1)
0.8 – 1.2 ml for 5 minutes at 3 000 r/min
CLUTCH
Clutch wheel I.D.
ITEM
Clutch shoe thickness
Clutch engagement
Clutch lock-up
STANDARD
110.00 – 110.15
3.0
4 100 – 4 500 r/min
5 600 – 6 200 r/min
Unit: mm
LIMIT
14.040
3.0
—
0.05
Unit: mm
LIMIT
110.50
2.0
—
—
Unit: mm
LIMIT
0.120
41.075
40.885
0.05
0.05
3.2
3.4
0.80
—
—
10.030
9.980
7-22 SERVICING INFORMATION
TRANSMISSION
ITEM
Reduction ratio
Final reduction ratio
Drive belt width
Driven face spring free length
CARBURETOR
Carburetor type
Bore size
I.D. No.
ITEM
Idle r/min
Float height
Main jet
Jet needle
Slow jet
Air screw
Throttle cable play
(M.J.)
(J.N.)
(S.J.)
(A.S.)
STANDARD
Variable 2.975 – 1.033
13.812 (51/15
× 65/16)
18.4
110
SPECIFICATION
KEIHIN PWS14
14 mm
30F0
1 900 ± 200 r/min
5.1 ± 0.5 mm
# 65
N5GJ-2nd
# 42
2 turns back
2 – 4 mm
Unit: mm Except ratio
LIMIT
—
—
17.4
104.5
SERVICING INFORMATION 7-23
ELECTRICAL
Spark plug
ITEM
Spark performance
Ignition coil resistance
Ignition coil primary peak voltage
Generator coil resistance
Pickup coil peak voltage
Regulated voltage
Generator maximum output
Starter relay resistance
Battery Type designation
Capacity
Standard electrolyte specific gravity
Fuse size
WATTAGE
ITEM
Headlight HI
LO
Brake light/Taillight
Turn signal light
Speedometer light
Fuel level indicator light
Turn signal indicator light
Oil level indicator light
High beam indicator light
License plate light
Type
Gap
Primary
Secondary
SPECIFICATION
NGK: BPR7HS
DENSO: W22FPR
0.6 – 0.7
Over 8 at 1 atm.
0.2 – 1.5
Ω
10 – 20 k
Ω
More than 150 V
Lighting
Charging
Pickup
0.3 – 1.5
Ω
0.5 – 2.0
Ω
120 – 250
Ω
More than 5.0 V
13.5 – 15.0 V at 5 000 r/min
125 W at 5 000 r/min
50 – 90
Ω
CB4L-B, FB4L-B
12 V 14.4 kC (4 Ah)/10 HR
1.280 at 20°C
10 A
SPECIFICATION
35
35
21/5
10
2
2
2
2
1.2
5
Unit: mm
NOTE
W/Bl – B/W
Plug cap-B/W
+: Ground
-: W/Bl
Y/W – Ground
W/R – Ground
W – Br
+: W -: Br
Unit: W
7-24 SERVICING INFORMATION
BRAKE + WHEEL
ITEM
Brake lever play
Brake drum I.D.
Brake disc thickness
Brake disc runout
Master cylinder bore
Master cylinder piston diameter
Brake caliper cylinder bore
Brake caliper piston diameter
Brake fluid type
Wheel rim runout
Wheel axle runout
Wheel rim size
Rear
Rear
Front
Front
Front
Front
Front
Front
Axial
Radial
Front
Front
Rear
STANDARD/SPECIFICATION
15 – 25
—
4.0 ± 0.2
—
11.000 – 11.043
10.957 – 10.984
30.230 – 30.306
30.150 – 30.200
DOT 4
—
—
—
J12
× MT3.50
J12
× MT3.50
TIRE
ITEM
Cold inflation tire pressure
Solo riding
Dual riding
(Except for UF50Z)
Tire size
Tire type
Tire tread depth
Front
Rear
Front
Rear
Front
Rear
Front
Rear
Front
Rear
STANDARD/SPECIFICATION
125 kPa (1.25 kgf/cm
2
)
175 kPa (1.75 kgf/cm 2 )
125 kPa (1.25 kgf/cm 2 )
230 kPa (2.30 kgf/cm 2 )
120/ 70-12 51L
130/ 70-12 56L
BRIDGESTONE: HOOP B02 G
BRIDGESTONE: HOOP B02
—
—
SUSPENSION
Front fork stroke
ITEM
Front fork spring free length
Rear wheel travel
STANDARD
77
124.7
60
Unit: mm
LIMIT
—
—
—
—
—
—
—
—
1.6
1.6
Unit: mm
LIMIT
—
122
—
—
—
2.0
2.0
0.25
—
—
Unit: mm
LIMIT
—
120.7
3.5
0.30
—
—
—
FUEL + OIL
ITEM
Fuel type
Fuel tank capacity
Engine oil type
Engine oil tank capacity
Final gear oil type
Final gear oil capacity
SERVICING INFORMATION 7-25
SPECIFICATION
Use only gasoline that is graded 91 octane or higher.
Unleaded gasoline is recommended.
6.0 L
Use SUZUKI CCI SUPER OIL. If not available, use a good quality 2-stroke oil rated FC under JASO classification.
1.2 L
SAE 10W-40
130 ml
NOTE
UF50K1 AND UF50ZK1 (’01-MODEL)
UF50K1 AND UF50ZK1 (’01-MODEL)
8-1
CONTENTS
SPECIFICATIONS ............................................................................................ 8- 2
SERVICE DATA ................................................................................................ 8- 4
WIRE HARNESS ROUTING ............................................................................ 8- 7
8
8-2 UF50K1 AND UF50ZK1 (’01-MODEL)
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ................................................... 1 840 mm
Overall width .................................................... 650 mm
Overall height ................................................... 1 095 mm
Wheelbase ....................................................... 1 255 mm
Ground clearance ............................................ 135 mm
Seat height ....................................................... 795 mm
Dry mass ..........................................................
83 kg
ENGINE
Type ................................................................. Two-stroke, forced air-cooled
Intake system ................................................... Reed valve
Number of cylinders ......................................... 1
Bore ................................................................. 41.0 mm
Stroke ............................................................... 37.4 mm
Piston displacement ........................................ 49 cm 3
Corrected compression ratio ........................... 7.2:1
Carburetor ........................................................ KEIHIN PWS14
Air cleaner ........................................................ Polyurethane foam element
Starter system .................................................. Electric and kick
Lubrication system ........................................... SUZUKI “CCI”
TRANSMISSION
Clutch ............................................................... Dry shoe, automatic, centrifugal type
Gearshifting ..................................................... Automatic, variable ratio
Gear ratios ....................................................... Variable reduction ratio... (2.975 – 1.033)
Final reduction ratio ......................................... 13.812 (51/15)
× (65/16)
Drive system .................................................... V-belt drive
UF50K1 AND UF50ZK1 (’01-MODEL) 8-3
CHASSIS
Front suspension ............................................. Inverted telescopic, coil spring
Rear suspension .............................................. Swingarm type, coil spring, oil damped
Steering angle .................................................. 45° (right & left)
Caster .............................................................. 25°30’
Trail .................................................................. 82 mm
Turning radius .................................................. 1.9 m
Front brake ....................................................... Disc brake
Rear brake ....................................................... Internal expanding
Front tire size ................................................... 120/70-12 51L
Rear tire size .................................................... 130/70-12 56L
ELECTRICAL
Ignition type ..................................................... Electronic ignition (CDI)
Spark plug ........................................................ NGK: BPR7HS or DENSO: W22FPR
Battery ............................................................. 12 V 14.4 kC (4 Ah)/10 HR
Generator ......................................................... Generator
Fuse ................................................................. 10 A
Headlight .......................................................... 12 V 35/35 W
Brake light/taillight ............................................ 12 V 21/5 W
Turn signal light ................................................ 12 V 10 W
CAPACITIES
Fuel tank .......................................................... 6.0 L
Engine oil tank ................................................. 1.2 L
Final gear oil .................................................... 130 ml
NOTE:
These specifications are subject to change without notice.
8-4 UF50K1 AND UF50ZK1 (’01-MODEL)
SERVICE DATA
CYLINDER + PISTON + PISTON RING
ITEM
Piston to cylinder clearance
Cylinder bore
Piston diam.
Cylinder distortion
Cylinder head distortion
Piston ring free end gap
Piston ring end gap
Piston ring to groove clearance
Piston pin bore
Piston pin O.D.
STANDARD
0.06 – 0.07
1st R
2nd R
1st &
2nd
R
1st
2nd
41.005 – 41.020
Measure at 20 mm from the top surface
40.940 – 40.955
Measure at 15 mm from the skirt end
———
———
Approx. 4.0
Approx. 4.3
0.10 – 0.25
0.03 – 0.07
0.02 – 0.06
10.002 – 10.010
9.995 – 10.000
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod deflection
Crank web to web width
Crankshaft runout
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pump discharge rate
STANDARD
14.003 – 14.011
———
36.0 ± 0.05
———
SPECIFICATION
30.000 (30/1)
0.8 – 1.2 ml for 5 minutes at 3 000 r/min.
CLUTCH
ITEM
Clutch wheel I.D.
Clutch shoe thickness
Clutch engagement
Clutch lock-up
TRANSMISSION
ITEM
Reduction ratio
Final reduction ratio
Drive belt width
Driven face spring free length
STANDARD
110.00 – 110.15
3.0
4 300 ± 200 r/min.
5 900 ± 300 r/min.
STANDARD
Variable 2.975 – 1.033
13.812 (51/15 × 65/16)
18.4
110
Unit: mm
LIMIT
0.120
41.075
40.885
0.05
0.05
3.2
3.4
0.80
———
———
10.030
9.980
Unit: mm
LIMIT
14.040
3.0
———
0.05
Unit: mm
LIMIT
110.50
2.0
———
———
Unit: mm Except ratio
LIMIT
———
———
17.4
104.5
UF50K1 AND UF50ZK1 (’01-MODEL) 8-5
CARBURETOR
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min.
Float height
Main jet
Jet needle
Slow jet
Air screw
Throttle cable play
(M.J.)
(J.N.)
(S.J.)
(A.S.)
ELECTRICAL
Spark plug
ITEM
Spark performance
Ignition coil resistance
Ignition coil primary peak voltage
Generator coil resistance
Pick-up coil peak voltage
Regulated voltage
Generator Max. output
Starter relay resistance
Battery Type designation
Capacity
Standard electrolyte S.G.
Fuse size
Type
Gap
Primary
Secondary
SPECIFICATION
NGK: BPR7HS
DENSO: W22FPR
0.6 – 0.7
Over 8 at 1 atm.
0.2 – 1.5
Ω
10 – 20 k
Ω
More than 150 V
Lighting
Charging
Pick-up
0.3 – 1.5
Ω
0.5 – 2.0
Ω
120 – 250
Ω
More than 5.0 V
13.5 – 15.0 V at 5 000 r/min.
125 W at 5 000 r/min.
50 – 90
Ω
CB4L-B
12 V 14.4 kC (4 Ah)/10 HR
1.280 at 20°C
10 A
WATTAGE
SPECIFICATION
KEIHIN PWS14
14 mm
30F0
1 900 ± 200 r/min.
5.1 ± 0.5 mm
#65
N5GJ-2nd
#42
2 turns back
2 – 4 mm
Headlight
ITEM
Brake light/Taillight
Turn signal light
Speedometer light
Turn signal indicator light
Oil level indicator light
Fuel level indicator light
High beam indicator light
License light
HI
LO
SPECIFICATION
35
35
21/5
10
2
2
2
2
1.2
5
Unit: mm
NOTE
W/Bl – B/W
Plug cap – B/W
: Ground
: W/Bl
Y/W – Ground
W/R – Ground
W – Br
: W : Br
Y/G – W
Unit: W
8-6 UF50K1 AND UF50ZK1 (’01-MODEL)
BRAKE + WHEEL
ITEM
Brake lever play
Brake drum I.D.
Brake disc thickness
Brake disc runout
Master cylinder bore
Master cylinder piston diam.
Brake caliper cylinder bore
Brake caliper piston diam.
Brake fluid type
Wheel rim runout
Wheel axle runout
Wheel rim size
Rear
Rear
Front
Front
Front
Front
Front
Front
Axial
Radial
Front
Front
Rear
STANDARD/SPECIFICATION
15 – 25
———
4.0 ± 0.2
———
11.000 – 11.043
10.957 – 10.984
30.230 – 30.306
30.150 – 30.200
DOT 4
———
———
———
J12 × MT3.50
J12 × MT3.50
TIRE
ITEM
COLD INFLATION TIRE
PRESSURE (SOLO RIDING)
COLD INFLATION TIRE
PRESSURE (DUAL RIDING)
(Except for UF50Z)
Tire size
Tire type
Tire tread depth
Front
Rear
Front
Rear
Front
Rear
Front
Rear
Front
Rear
STANDARD/SPECIFICATION
125 kPa (1.25 kgf/cm
2
, 18 psi)
175 kPa (1.75 kgf/cm 2 , 25 psi)
125 kPa (1.25 kgf/cm 2 , 18 psi)
230 kPa (2.30 kgf/cm
2
, 33 psi)
120/70-12 51L
130/70-12 56L
BRIDGESTONE: HOOP B02 G
BRIDGESTONE: HOOP B02
———
———
SUSPENSION
ITEM
Front fork stroke
Front fork spring free length
Rear wheel travel
FUEL + OIL
ITEM
Fuel type
Fuel tank capacity
Engine oil type
Engine oil tank capacity
Final gear oil type
Final gear oil capacity
STANDARD
77
124.7
60
SPECIFICATION
Gasoline used should be graded 91 octane or higher. An unleaded gasoline is recommended.
6.0 L
Use SUZUKI CCI SUPER OIL. If they are not available, use a good quality 2-stroke oil rated
FC under JASO classification.
1.2 L
SAE 10W/40
130 ml
LIMIT
———
———
———
———
———
———
———
———
1.6
1.6
Unit: mm
LIMIT
———
122
———
Unit: mm
LIMIT
———
120.7
3.5
0.30
———
———
———
———
———
2.0
2.0
0.25
———
———
NOTE
WIRE HARNESS ROUTING
Brake light/taillight
W (White) lead wire
UF50K1 AND UF50ZK1 (’01-MODEL) 8-7
1 Set the wires under the bracket seat striker and the tube frame.
Clamp
Brake light/taillight coupler
Gr (Gray) lead wire B/W (Black with White tracer) lead wire
Fuel level indicator switch coupler
License plate light coupler
VIEW
Rear turn signal light lead wire
CDI unit
Ignition coil
Fuel valve
Generator coupler
Clamp
Wire harness
Thermoswitch coupler
Clamp
Wiring harness
Clamp
Clamp
Wire harness
Generator coupler
Clamp
Oil level indicator switch coupler
Wiring harness
Clamp
Air vent hose
Wire harness
Front brake hose
Rear brake cable
Speedometer cable
Throttle cable
Clamp
Clamp
Starter relay
battery terminal
Fuse box
Fuel valve
VIEW
battery terminal
Prepared by
Motorcycle Service Department
2nd Ed. March, 2001
1st Ed. April, 2000
Part No. 99500-10491-01E
Printed in Japan
188
Printed in Japan
Y K1

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Key features
- 99,500-10,491-01E serial number
- UF50Z model
- Advanced engine with high power output
- User-friendly design
- Comfortable seat position