2004 Suzuki 250 LTZ Quad Sport Service Manual

User Manual: 2004 Suzuki 250 LTZ Quad Sport Service Manual

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FOREWORD

GROUP INDEX
GENERAL INFORMATION

PERIODIC MAINTENANCE

ENGINE

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This manual contains an introductory description on
the SUZUKI LT-Z250 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 vehicle 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 vehicle 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 vehicle.
* Illustrations in this manual are used to show
the basic principles of operation and work
procedures. They may not represent the
actual vehicle exactly in detail.
* This manual is written for persons who have
enough knowledge, skills and tools, including
special tools, for servicing SUZUKI vehicles.
If you do not have the proper knowledge and
tools, ask your authorized SUZUKI motorcycle dealer to help you.

DRIVE TRAIN

FUEL SYSTEM

LUBRICATION SYSTEM

CHASSIS

ELECTRICAL SYSTEM

SERVICING INFORMATION



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 vehicle
unsafe for the rider.

' COPYRIGHT SUZUKI MOTOR CORPORATION 2003

99500-42175-03E

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03 ENGINE.book Page 105 Tuesday, February 28, 2006 3:03 PM

SUPPLEMENTS
10

LT-Z250K6 ( 06-MODEL)

LT-Z250K7 ( 07-MODEL)

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LT-Z250K5 ( 05-MODEL)

LT-Z250K8 ( 08-MODEL)

LT-Z250K9 ( 09-MODEL)

HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE LOOKING FOR:

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1. The text of this manual is divided into sections.
2. The section titles are listed in the GROUP INDEX.
3. Holding the manual as shown at the right will allow you to find
the first page of the section easily.
4. The contents are listed on the first page of each section to
help you find the item and page you need.

COMPONENT PARTS AND WORK TO BE DONE

Under the name of each system or unit there is an exploded view which provides work instructions and other
service information (e.g.; tightening torque, lubricating points and locking agent points).
Example: Rear suspension

1 Rear shock absorber
2 Swingarm
3 Bearing
A Rear shock absorber mounting nut (Upper)
B Rear shock absorber mounting nut (Lower)
C Swingarm pivot nut
D Axle housing mounting nut (RH)
E Axle housing bolt
F Axle housing mounting nut (LH)

ITEM

N•m

kgf-m

lb-ft

7.8

55.0

6.0

43.5

A
B
C
D
EF

85
60

8.5

61.5

6.0

43.5

6.5

47.0

SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table.
SYMBOL

DEFINITION

Indicates service data.

Apply THREAD LOCK SUPER 1322 .
99000-32110 (Except USA)

Apply oil. Use engine oil unless
otherwise specified.

Apply THREAD LOCK 1342 .
99000-32050

Apply hypoid gear oil.

Apply THREAD LOCK SUPER 1360 .
99000-32130

Apply molybdenum oil solution.
(mixture of engine oil and SUZUKl
MOLY PASTE in a ratio of 1 : 1)

Apply or use brake fluid.

Apply SUZUKI SUPER GREASE A .
99000-25030 (USA)
99000-25010 (Others)

Measure in voltage range.

Apply SUZUKI SILICONE GREASE.
99000-25100

Measure in resistance range.

Apply SUZUKI MOLY PASTE.
99000-25140

Measure in current range.

Apply WATER RESISTANCE GREASE.
99000-25160

Measure in diode test range.

Apply SUZUKI BOND 1207B
99104-31140 (USA)
99000-31140 (Others)

Measure in continuity test range.

Apply SUZUKI BOND 1215 .
99000-31110 (Except USA)

Use special tool.

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Apply THREAD LOCK SUPER 1303 .
99000-32030

P
1216B

DEFINITION

Torque control required.
Data beside it indicates specified
torque.

H/O
W

SYMBOL

Apply SUZUKI BOND 1216B .
99000-31230

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GENERAL INFORMATION

1-1

GENERAL INFORMATION
1
CONTENTS

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WARNING/CAUTION/NOTE .........................................................................1GENERAL PRECAUTIONS ...........................................................................1SUZUKI LT-Z250K4 (2004-MODEL) .............................................................1SERIAL NUMBER LOCATION ......................................................................1FUEL AND OIL RECOMMENDATION ..........................................................1FUEL (FOR CANADA AND USA) ..........................................................1FUEL (FOR THE OTHER COUNTRIES) ................................................1ENGINE OIL (FOR USA) ........................................................................1ENGINE OIL (FOR THE OTHER COUNTRIES) ....................................1REAR DRIVE GEAR OIL .......................................................................1BRAKE FLUID ........................................................................................1BREAK-lN PROCEDURES ...........................................................................1INFORMATION LABELS ...............................................................................1SPECIFICATIONS .........................................................................................1DIMENSIONS AND DRY MASS ............................................................1ENGINE ..................................................................................................1DRIVE TRAIN .........................................................................................1CHASSIS ................................................................................................1ELECTRICAL .........................................................................................1CAPACITIES ..........................................................................................1COUNTRY AND AREA CODES ....................................................................1-

2
2
4
4
4
4
4
5
5
5
5
5
6
7
7
7
7
8
8
8
9

1-2

GENERAL INFORMATION

WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol
and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words.
!
Indicates a potential hazard that could result in death or injury.
"

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Indicates a potential hazard that could result in vehicle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.

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

GENERAL PRECAUTIONS
!

* Proper service and repair procedures are important for the safety of the service mechanic and
the safety and reliability of the vehicle.
* 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 handling toxic or flammable materials, make sure that the area you work in is well ventilated and that you follow all of the manufacturer s instructions.
* Never use gasoline as a cleaning solvent.
* To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system
until they have cooled.
* After servicing the fuel, oil, exhaust or brake systems, check all of the lines, and fittings
related to the system for leaks.

GENERAL INFORMATION

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* If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent.
* When removing parts that are to be reused, keep them arranged in an orderly manner so that
they may be reinstalled in the proper order and orientation.
* Be sure to use special tools when instructed.
* Make sure that all parts used in reassembly are clean. Lubricate them when specified.
* Use the specified lubricant, bond or sealant.
* When removing the battery, disconnect the negative cable first and then the positive cable.
* When reconnecting the battery, connect the positive cable first and then the negative cable,
and replace the terminal cover on the positive terminal.
* When performing service to electrical parts, if the service procedures not require use of battery power, disconnect the negative cable the battery.
* When tightening the cylinder head and case bolts and nuts, tighten the larger sizes first.
Always tighten the bolts and nuts diagonally from the inside toward outside and to the specified tightening torque.
* Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking
nuts, cotter pins, circlips and certain other parts as specified, be sure to replace them with
new ones. Also, before installing these new parts, be sure to remove any left over material
from the mating surfaces.
* Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger
than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is
completely seated in its groove and securely fitted.
* Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a
thread is smeared with them.
* After reassembling, check parts for tightness and proper operation.

* To protect the environment, do not unlawfully dispose of used motor oil, all other fluids, batteries and tires.
* To protect the earth s natural resources, properly dispose of used vehicles and parts.

1-3

1-4

GENERAL INFORMATION

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SUZUKI LT-Z250K4 (2004-MODEL)

RIGHT SIDE

LEFT SIDE

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

SERIAL NUMBER LOCATION

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

FUEL AND OIL RECOMMENDATION
FUEL (FOR CANADA AND USA)

Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) method or 91 octane or higher rated
by the Research Method.
SUZUKI recommends that customers use alcohol-free unleaded gasoline whenever possible.
Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted.
Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than 10% ethanol. Gasoline/alcohol fuel may contain up to 5% methanol if appropriate cosolvents and corrosion inhibitors are present in it.
If the performance of the vehicle is unsatisfactory while using blended gasoline/alcohol fuel, you should
switch to alcohol-free unleaded gasoline.
Failure to follow these guidelines could possibly void applicable warranty coverage. Check with your fuel
supplier to make sure that the fuel you intend to use meets the requirements listed above.

FUEL (FOR THE OTHER COUNTRIES)
Use unleaded gasoline that is graded 91 octane or higher by the Research Method.

GENERAL INFORMATION

1-5

ENGINE OIL (FOR USA)
SUZUKI recommends the use of SUZUKI PERFORMANCE 4
MOTOR OIL or oils that meet API service classifications SF or
SG and that have a viscosity rating of SAE 10W-40. If engine oil
with a rating of SAE 10W-40 is not available, select an alternative according to the chart.

ENGINE OIL (FOR THE OTHER COUNTRIES)

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Use a premium quality 4-stroke motor oil to ensure longer service life of the vehicles. Use only oils that meet API service classifications SF or SG and that have a viscosity rating of SAE
10W-40. If engine oil with a rating of SAE 10W-40 is not available, select an alternative according to the chart.

REAR DRIVE GEAR OIL

Use hypoid gear oil that meets the API service classification GL-5 and is rated SAE #90. Use a hypoid gear
oil with a rating of SAE #80 if the vehicle is operated where the ambient temperature is below 0 C (32 F).

BRAKE FLUID

# Specification and classification: DOT 4
!

This vehicle uses a glycol-based brake fluid. Do not use or mix different types of brake fluid
such as silicone-based and petroleum-based fluids for refilling the system, otherwise serious
damage will result to the brake system.
Never use any brake fluid taken from old, used or unsealed containers.
Never reuse brake fluid left over from the last servicing or which has been stored for a long
period of time.

BREAK-lN 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-lN 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 engine speed limits.
Break-in engine speeds
Initial 10 hours: Less than ‰ throttle
After the engine has been operated for 10 hours the engine to full throttle operation, for short periods of
time.

1-6

GENERAL INFORMATION

INFORMATION LABELS
No.

LABEL or PLATE NAME

APPLIED SPECIFICATION
E-19
E-28
E-33

Certification plate E

Information label E

Gearshift pattern label E

Gearshift pattern label E/F

Tire air pressure label E

Tire air pressure label and warning no-passenger label F

General warning label E

General warning label F

Warning no-passenger label E

Age, 16 Iabel E

Age, 16 Iabel F

Manual notice label E

Gearshift label E

Gearshift label F

ICES Canada label E/F

Compliance label E

EC approval mark

A
A
A
A

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* E-28: Fuel caution label enclosed.
E: English
F: French
A: Attached

Left side frame

Front of left side frame

A
A

GENERAL INFORMATION

SPECIFICATIONS
DIMENSIONS AND DRY MASS

ENGINE

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Overall length ...................................................... 1 720 mm (67.7 in)
Overall width ....................................................... 1 070 mm (42.1 in)
Overall height ...................................................... 1 090 mm (42.9 in)
Wheelbase .......................................................... 1 135 mm (44.7 in)
Front track ........................................................... 830 mm (32.7 in)
Rear track............................................................ 810 mm (31.9 in)
Ground clearance................................................ 230 mm ( 9.1 in)
Seat height .......................................................... 810 mm (31.9 in)
Dry mass ............................................................. 166 kg (365 lbs)

Type .................................................................... Four-stroke, air-cooled, OHC
Number of cylinders ............................................ 1
Bore..................................................................... 66.0 mm (2.598 in)
Stroke .................................................................. 72.0 mm (2.835 in)
Displacement ...................................................... 246 cm‡ (15.0 cu. in)
Compression ratio ............................................... 9.2 : 1
Carburetor ........................................................... MIKUNI BSR29, single
Air cleaner ........................................................... Polyurethane foam element
Starter system ..................................................... Electric
Lubrication system .............................................. Wet sump
Idle speed............................................................ 1 500 – 100 r/min

DRIVE TRAIN

Clutch .................................................................. Wet multi-plate, automatic, centrifugal type
Transmission....................................................... 5-forward and 1-reverse
Gearshift pattern, forward ................................... All up, foot lever operated
reverse ................................... Foot/hand operated
Primary reduction ratio ........................................ 3.047 (64/21)
Secondary reduction ratio ................................... 1.133 (17/15)
Gear ratios, 1st ................................................... 3.083 (37/12)
2nd .................................................. 1.933 (29/15)
3rd ................................................... 1.388 (25/18)
4th ................................................... 1.095 (23/21)
5th ................................................... 0.913 (21/23)
Reverse........................................... 2.833 (34/12)
Final reduction ratio............................................. 3.200 (32/10)

1-7

1-8

GENERAL INFORMATION

CHASSIS

ELECTRICAL

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Front suspension .................................................Independent, double wishbone, coil spring, oil damped
Rear suspension ..................................................Swingarm type, coil spring, oil damped
Front wheel travel ................................................160 mm (6.3 in)
Rear wheel travel .................................................170 mm (6.7 in)
Caster ..................................................................7 40 ......... 1G
Trail ......................................................................33 mm (1.30 in) ........1G
Toe-in...................................................................5 mm (0.20 in) ..........1G
Steering angle......................................................45
Turning radius ......................................................2.7 m (8.9 ft)
Front brake...........................................................Disc brake, twin
Rear brake ...........................................................Drum brake
Front tire size .......................................................AT22 7-10 ✩✩, tubeless
Rear tire size........................................................AT20 10-9 ✩, tubeless

lgnition type..........................................................Electronic ignition (CDl)
lgnition timing .......................................................5 B.T.D.C. at 1 500 rpm
Spark plug............................................................NGK DR7EA or DENSO X22ESR-U
Battery..................................................................12 V 28.8 kC (8 Ah)/10 HR
Generator.............................................................Three-phase A.C. generator
Main fuse .............................................................20/15 A
Headlight..............................................................12 V 40/40 W
Brake light/Taillight...............................................12 V 21/5 W
Neutral indicator light ...........................................12 V 3 W
Reverse indicator light .........................................12 V 3 W

CAPACITIES

Fuel tank, including reserve ...............................10.6 L (2.8/2.3 US/Imp gal)
reserve .............................................. 2.6 L (0.7/0.6 US/Imp gal)
Engine oil, oil change ..........................................2 200 ml (2.3/1.9 US/Imp qt)
filter change.......................................2 300 ml (2.4/2.0 US/Imp qt)
overhaul.............................................2 500 ml (2.6/2.2 US/Imp qt)
Final gear oil, oil change ...................................... 190 ml (6.4/6.7 US/Imp oz)
NOTE:
* These specifications are subject to change without notice.

GENERAL INFORMATION

COUNTRY AND AREA CODES
The following codes stand for the applicable countries and areas:
COUNTRY OR AREA
EU
Canada
USA and California

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CODE
E-19
E-28
E-33

1-9

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PERIODIC MAINTENANCE

2-1

PERIODIC MAINTENANCE

CONTENTS

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PERIODIC MAINTENANCE SCHEDULE .......................................................2- 2
PERIODIC MAINTENANCE CHART .....................................................2- 2
MAINTENANCE AND TUNE-UP PROCEDURES ..........................................2- 3
AIR CLEANER .......................................................................................2- 3
EXHAUST PIPE NUTS AND MUFFLER BOLTS ...................................2- 5
VALVE CLEARANCE ............................................................................2- 5
SPARK PLUG ........................................................................................2- 7
FUEL LINE .............................................................................................2- 8
THROTTLE CABLE PLAY .....................................................................2- 9
ENGINE IDLE SPEED ............................................................................2- 9
ENGINE OIL AND OIL FILTER ..............................................................2-10
FINAL GEAR OIL ...................................................................................2-11
SPARK ARRESTER ...............................................................................2-12
CLUTCH .................................................................................................2-13
BRAKES .................................................................................................2-14
BRAKE FLUID ........................................................................................2-15
BRAKE HOSE ........................................................................................2-17
TIRES .....................................................................................................2-17
STEERING ..............................................................................................2-19
SUSPENSIONS ......................................................................................2-19
CHASSIS BOLTS AND NUTS ...............................................................2-20
GENERAL LUBRICATION .....................................................................2-23
COMPRESSION PRESSURE CHECK ............................................................2-24
COMPRESSION TEST PROCEDURE ...................................................2-24
OIL PRESSURE CHECK .................................................................................2-25
OIL PRESSURE TEST PROCEDURE ...................................................2-25
INITIAL ENGAGEMENT AND CLUTCH LOCK-UP INSPECTION .................2-26
INITIAL ENGAGEMENT INSPECTION ..................................................2-26
CLUTCH LOCK-UP INSPECTION .........................................................2-26

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 vehicle operating at peak performance and economy.
NOTE:
More frequent servicing may be performed on vehicles that are use under severe conditions.

PERIODIC MAINTENANCE CHART
Interval

Spark plug

Engine oil and oil filter
Final gear oil

3 months
C
T
I

6 months
C
T
I
I

T
I

I
I

I
Replace every 2 years.

Tires
Suspensions
Steering
Chassis bolts and nuts
General lubrications

C
I
I
I
R
I

Replace every 2 years.

Brake hose

1 month

I
Replace every 4 years.

Fuel line

Brake fluid

Every

Replace every 18 months.

Spark arrester
Engine idle speed
Throttle cable play

Clutch
Brakes

Every

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Item
Air cleaner
Exhaust pipe nuts and muffler bolts
Valve clearance

Initial

Replace every 4 years.
I

I
T
L

I = Inspect and adjust, clean, lubricate or replace as necessary
R = Replace
T = Tighten
C = Clean
L = Lubricate

I
T
L

I
I
I
I
I
I
I
T
L

PERIODIC MAINTENANCE

MAINTENANCE AND TUNE-UP PROCEDURES
This section describes the servicing procedures for each item
mentioned in the Periodic Maintenance chart.

AIR CLEANER
Clean every 3 months.

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If the air cleaner is clogged with dust, intake resistance will be
increased, with a resultant decrease in power output and an
increase in fuel consumption. Check and clean the air cleaner
element in the following manner:
Remove the seat. (!7-5)
Disconnect the air vent hose 1.
Remove the air cleaner case cover 2.

NOTE:
Be careful not to drop the O-ring into the air cleaner box that is
attached to the air cleaner case cover.

Remove the air cleaner element 3.

Separate the polyurethane foam element 4, element frame
5 and element holder 6.

2-3

2-4

PERIODIC MAINTENANCE

Fill a wash pan of a proper size with a non-flammable cleaning solvent. Immerse the air cleaner element in the cleaning
solvent and wash it.
Press the air cleaner element between the palms of both
hands to remove the excess solvent: do not twist or wring the
element, or it will tear.
Immerse the element in motor oil, and then squeeze out the
excess oil leaving the element slightly wet.
A Non-flammable cleaning solvent
B Motor oil SAE #30 or SAE 10W-40

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"
* Inspect the air cleaner element for tears. A torn element must be replaced.
* If driving under dusty conditions, clean the air
cleaner element more frequently. The surest way to
accelerate engine wear is to operate the engine without the element or with torn element. Make sure that
the air cleaner element is in good condition at all
times. Life of the engine depends largely on this
component!

Remove the drain cap 7 of the air cleaner box to allow any
water to drain out.

PERIODIC MAINTENANCE

EXHAUST PIPE NUTS AND MUFFLER
BOLTS
Tighten initially at 1 month and every 3 months thereafter.
Tighten the exhaust pipe nuts 1 and muffler mounting bolts/
nuts 2.
Remove the right footrest mud guard. (!7-7)
Tighten the muffler connecting bolt 3.

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# Exhaust pipe nut: 23 N•m (2.3 kgf-m, 16.5 lb-ft)
Muffler connecting bolt: 23 N•m (2.3 kgf-m, 16.5 lb-ft)
Muffler mounting bolt/nut: 23 N•m (2.3 kgf-m, 16.5 lb-ft)

VALVE CLEARANCE

Inspect initially at 1 month and every 3 months thereafter.

Excessive valve clearance results in valve noise and insufficient
valve clearance results in valve damage and reduced power.
Check the intake and exhaust valve clearances at the distances
indicated above and adjust the valve clearances to specification,
if necessary.
Remove the fuel tank. (!5-3)
Remove the spark plug. (!2-7)

$ 09930-10121: Spark plug wrench set
Remove the valve timing inspection plug 1 and generator
cover cap 2.

2-5

2-6

PERIODIC MAINTENANCE

Remove the valve inspection caps 3.

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NOTE:
Valve clearance is to be checked when the engine is cold.
The intake and exhaust valves must be checked and adjusted
when the piston is at Top-Dead-Center (TDC) on the compression stroke.
Turn the crankshaft until the TDC line 4 on the generator
rotor aligns with the index mark 5 on the crankcase.

Insert the thickness gauge between the valve stem end and
adjusting screw on the rocker arm to check the clearance.
If the clearance is out of specification, bring it into the specified range.
% Valve clearance (when cold)
IN: 0.03 0 .08 mm (0.001 0. 003 in)
EX: 0.08 0 .13 mm (0.003 0. 005 in)

$ 09900-20803: Thickness gauge or
09900-20804: Thickness gauge

Securely tighten the locknut after completing adjustment.

# Valve clearance adjuster locknut:
14 N•m (1.4 kgf-m, 10.0 lb-ft)
Install the spark plug, valve timing inspection plug and generator cover cap to the specified torque of each.
# Spark plug: 18 N•m (1.8 kgf-m, 13.0 lb-ft)
Valve timing inspection plug:
23 N•m (2.3 kgf-m, 16.5 lb-ft)
Generator cover cap: 15 N•m (1.5 kgf-m, 11.0 lb-ft)

PERIODIC MAINTENANCE

Apply grease to new O-rings and install them to the valve
inspection caps.
& 09900-25030: SUZUKI SUPER GREASE A ( USA)
09900-25010: SUZUKI SUPER GREASE A ( Others)
Tighten the valve inspection caps.

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SPARK PLUG

Inspect every 6 months.
Replace every 18 months.

SPARK PLUG REMOVAL
Disconnect the spark plug cap 1 and remove the spark plug.
$ 09930-10121: Spark plug wrench set

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

Standard

Colder type

NGK

DENSO

DR7EA

X22ESR-U

DR8EA

X24ESR-U

CARBON DEPOSITS
Check to see if there are carbon deposits on the spark plug. If
carbon is deposited, remove it using a spark plug cleaner
machine or carefully use a tool with a pointed end.

2-7

2-8

PERIODIC MAINTENANCE

SPARK PLUG GAP
Measure the spark plug gap using the thickness gauge. If the
spark plug gap is out of specification, adjust the gap.
% Standard
Spark plug gap: 0.6

0.7 mm (0.024

0.028 in)

$ 09900-20803: Thickness gauge or
09900-20804: Thickness gauge

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ELECTRODE
Check the condition of the electrode.
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 thread size and reach of 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.

# Spark plug: 18 N•m (1.8 kgf-m, 13.0 lb-ft)

FUEL LINE

0.6 0.7 mm
(0.024 0.028 in)

Inspect every 3 months.
Replace every 4 years.

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

PERIODIC MAINTENANCE

THROTTLE CABLE PLAY
Inspect initially at 1 month and every 3 months thereafter.
Adjust the throttle cable play A as follows:
Loosen the locknut 1 of the throttle cable.
Turn the adjuster 2 in or out to obtain the correct play.
% Throttle cable play A: 3

5 mm (0.12

0.20 in)

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After adjusting the throttle cable play, tighten the locknut 1.

ENGINE IDLE SPEED

Inspect initially at 1 month and every 3 months thereafter.
NOTE:
Make this adjustment when the engine is fully warm.

Connect the electric tachometer or the multi circuit tester to
the high-tension cord.

Start the engine and set the engine idle speed between 1 400
and 1 600 r/min by turning the throttle stop screw knob 1.

% Engine idle speed: 1 500 – 100 r/min

$ 09900-25008: Multi circuit tester set or
09900-26006: Tachometer

2-9

2-10

PERIODIC MAINTENANCE

ENGINE OIL AND OIL FILTER
Replace initially at 1 month and every 6 months thereafter.
The oil should be changed while the engine is warm. Oil filter
replacement should be done together with the engine oil change
at the intervals shown above.

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ENGINE OIL REPLACEMENT
Place an oil pan under the engine oil drain plug 1, and then
drain out the engine oil by removing the engine oil drain plug
1 and engine oil filler cap 2.
Tighten the engine oil drain plug 1 to the specified torque,
and then pour new engine oil through the oil filler hole. When
performing an oil change (without oil filter replacement), the
engine will hold about 2.2 L (2.3 US qt, 1.9 lmp qt) of oil. Use
the engine oil that meets the API service classifications SF or
SG and that has the viscosity rating of SAE 10W-40.
# Engine oil drain plug: 21 N•m (2.1 kgf-m, 15.0 lb-ft)

Install the oil filler cap 2.
Start the engine and allow the engine to run for a few minutes
at idling speed.

Turn off the engine and wait about three minutes, and then
check the oil level on the dipstick 3. If the level is below
upper line, add oil to that level. The vehicle must be in a level
position for an accurate measurement.

OIL FILTER REPLACEMENT
Drain engine oil. (!Above)
Remove the oil filter cap 1.
Remove the oil filter and O-rings.

PERIODIC MAINTENANCE

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Apply engine oil lightly to new O-rings A and B before installing the oil filter cap.
Install the new O-ring A onto the oil filter fitting boss of the
clutch cover.
Install the new O-ring B to the groove of the oil filter cap.
Install new oil filter 2.
Install the spring 3 and oil filter cap 4.
Pour new engine oil through the oil filler. When performing the
oil filter change, the engine will hold about 2.3 L (2.4 US qt,
2.0 Imp qt) of oil.
After three minutes of engine idling, check the oil level.
(!2-10)
% Engine oil capacity
Oil change: 2.2 L (2.3 US qt, 1.9 lmp qt)
Oil and filter change: 2.3 L (2.4 US qt, 2.0 lmp qt)
Engine overhaul: 2.5 L (2.6 US qt, 2.2 lmp qt)
"

When reassembling the oil filter, make sure that the oil
filter is installed as shown above. If the filter is
installed improperly, serious engine damage may
result.

FINAL GEAR OIL

Inspect every 6 months.
Replace every 2 years.

To change the final gear oil, locate the vehicle on a level position
and carry out the following steps. Use SAE #90 hypoid gear oil
which is rated GL-5 under the API classification system. Use
hypoid gear oil SAE #80, API grade GL-5, if the vehicle is ridden
where the ambient temperature is below 0 C or 32 F.

Remove the final gear case under cover 1 by removing three
bolts.

2-11

2-12

PERIODIC MAINTENANCE

Place an oil pan under the final gear case, and then drain oil
by removing the drain plug 2 and filler plug 3.
Tighten the drain plug 2.
Remove the oil level check plug 4 and pour the specified oil
through the filler hole until the oil over flows from the oil level
check hole.
Tighten the filler plug 3 and the oil level check plug 4.

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% Final gear oil capacity:
190 ml (6.42 US oz, 6.69 lmp oz)
# Final gear oil drain plug: 26 N•m (2.6 kgf-m, 19.0 lb-ft)
Final gear oil filler plug: 26 N•m (2.6 kgf-m, 19.0 lb-ft)

SPARK ARRESTER
Clean every 6 months.

Remove the spark arrester bolt 1.
Extract the spark arrester 2 from the muffler.

Clean the spark arrester 2 with a brush.

Only clean the spark arrester in an open area away
from combustible materials. Exhausted hot carbon
particles can start a fire.
Reinstall the spark arrester 2.
Tighten the spark arrester bolt to the specified torque.
# Spark arrester bolt: 11 N•m (1.1 kgf-m, 8.0 lb-ft)

PERIODIC MAINTENANCE

CLUTCH
Adjust every 6 months.
Remove the clutch adjuster cap 1.

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NOTE:
Adjust the clutch release, when the engine is cold.

Loosen the locknut 2.
Tighten the adjusting screw 3 until it stops.
Loosen the adjusting screw 3 1/16 1 /8 turn.
Tighten the locknut 2 to the specified torque while holding
the adjusting screw 3.
# Locknut 2: 23 N•m (2.3 kgf-m, 16.5 lb-ft)

Apply engine oil to the O-ring and cap thread lightly.
Tighten the clutch adjuster cap to the specified torque.

# Clutch adjuster cap: 15 N•m (1.5 kgf-m, 11.0 lb-ft)

2-13

2-14

PERIODIC MAINTENANCE

BRAKES
Inspect initially at 1 month and every 3 months thereafter.
BRAKE PADS
Remove the front wheels. (!7-11)
The extent of brake pad wear can be checked by observing the
limit line 1 on the side of brake pads. When the wear reaches
the limit line, replace the pads with new ones. (!7-19)

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

BRAKE SHOES
This vehicle is equipped with the brake lining indicator on the
rear brake.
To check the wear of the rear brake lining, perform the following
steps:
Make sure that the rear brake system is properly adjusted.
With fully applying the rear brake, check if the indicator plate
1 is within the range 2 embossed on the brake panel.
If the indicator plate 1 is out of the range 2, the brake shoe
assembly should be replaced with new ones. (!7-46)
REAR BRAKE PEDAL AND LEVER
The procedure for adjusting the rear brake pedal and brake
lever is as follows:

NOTE:
First adjust the brake pedal and next adjust the brake lever.

Brake pedal (Major brake adjustment)
Check that the brake pedal play A is within the specified range.
If the play is not within the specified range, make adjustments.
% Brake pedal play A: 20

30 mm (0.8 1 .2 in)

Turn the adjuster 1 until the play A reaches 20 30 m m (0.8
1 .2 in).

PERIODIC MAINTENANCE

Rear brake lever (Minor brake adjustment)
After adjusting the brake pedal, check the rear brake lever
play. The brake lever play B as measured at the lever holder
should be between 3 5 mm (0.1 0.2 in) when the lever is
lightly pulled in towards the grip. If adjustment is necessary,
slacken the cable by loosening the locknut 1 and screwing
the adjuster 2 on the brake lever holder all the way in. After
adjusting the play, tighten the locknut 1.
% Rear brake lever play B: 3

5 mm (0.1 0.2 in )

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BRAKE FLUID

Inspect every 3 months.
Replace every 2 years.

BRAKE FLUID LEVEL
Place the handlebar straight.
Check the brake fluid level by observing the lower limit line on
the front brake fluid reservoir.
When the brake fluid level is below the lower limit line, replenish with brake fluid that meets the following specification.
( Specification and classification: DOT 4
'

* The brake system of this vehicle is filled with a glycol-based brake fluid. Do not use or mix different
types of fluid such as silicone-based and petroleum-based fluids. Do not use any brake fluid taken
from old, used or unsealed containers. Never reuse
brake fluid left over from the last servicing or stored
for a long period of time.
* Brake fluid, if it leaks, will interfere with safe running
and immediately discolor painted surfaces. Check
the brake hoses and hose joints for cracks and oil
leakage before riding.

2-15

2-16

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 and thus interferes with the full braking performance of the
brake caliper. The presence of air is indicated by sponginess
of the brake lever and also by lack of braking force. Considering
the danger to which such trapped air exposes the machine and
rider, it is essential that after remounting the brake and restoring
the brake system to the normal condition, the brake fluid circuit
be purged of air in the following manner:

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Fill the front brake reservoir with the specified brake fluid to
the top of the inspection window or the upper limit line.
Replace the reservoir cap to prevent dirt from entering.
Attach a hose to the air bleeder valve, and insert the free end
of the hose into a receptacle.

Squeeze and release the brake lever several times in rapid
succession and hold the lever fully squeezed. Loosen the air
bleeder valve for about a quarter of a turn so that the brake
fluid runs into the receptacle, this will remove the tension of
the brake lever causing it to touch the handlebar grip. Then,
close the air bleeder valve, pump and squeeze the lever and
open the valve. Repeat this process until the fluid flowing into
the receptacle contains no air bubbles.

NOTE:
While bleeding the brake system, replenish the brake fluid in the
reservoir as necessary. Make sure that there is always some
fluid visible in the reservoir.
Close the air bleeder valve and disconnect the hose. Fill the
reservoir with brake fluid to the top of the inspection window
or the upper limit line.
# Air bleeder valve: 6 N•m (0.6 kgf-m, 4.4 lb-ft)
"
Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials, etc.

PERIODIC MAINTENANCE

BRAKE HOSE
Inspect every 6 months.
Replace every 4 years.

TIRES

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Check the brake hoses for leakage, cracks, wear and damage. If any damages are found, replace the brake hoses with
new ones.

Inspect every 3 months.

TIRE TREAD CONDITION
Operating the vehicle with excessively worn tires will decrease
riding stability and consequently cause a dangerous situation. It
is highly recommended to replace a tire when the remaining
depth of the tire tread reaches the following specification.
% Service Limit
Tire tread depth: Front 4.0 mm (0.16 in)
Rear 4.0 mm (0.16 in)
$ 09900-20805: Tire depth gauge

4.0 mm
(0.16 in)

2-17

2-18

PERIODIC MAINTENANCE

TIRE PRESSURE
If the tire pressure is too high or too low, steering will be
adversely affected and tire wear will increase. Therefore, maintain the correct tire pressure for good roadability and a longer
tire life. Cold inflation tire pressure is as follows.
COLD INFLATION TIRE PRESSURE
FRONT
REAR

kPa
30
25

kgf/cm2
0.30
0.25

psi
4.4
3.6

VEHICLE LOAD CAPACITY LIMIT: 110 kg (243 lbs)

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"
To minimize the possibility of tire damage from
over-inflation, we strongly recommended that a manual type air pump be used rather than a high pressure
air compressor as found in service stations. When filling air into the tires, never exceed 70 kPa (0.7 kgf/cm†,
10 psi).
"

The standard tire fitted on this vehicle is an AT22
7-10 ✩✩ for the front and a AT20 10-9 ✩ 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

STEERING
Inspect initially at 1 month and every 3 months thereafter.
Steering system should be adjusted properly for smooth handling of the handlebars and safe running.

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TOE-IN
Place the vehicle on level ground.
Make sure the tire pressure for right and left tires is same and
set to the proper specification.
Set the front wheels in the straight position.
Place a load of 75 kg (165 lbs) on the seat.

Measure the distance A and B of the front wheels with a
toe-in gauge as shown and calculate the difference A B.

% Toe-in: 5 – 4 mm (0.20 – 0.16 in)

If the toe-in is out of specification, bring it into the specified
range. (!7-43)

Forward

SUSPENSIONS

Inspect every 6 months.

Inspect the suspension arms and bushings for scratches,
wear or damage. If any damages are found, replace the suspension arm or bushing with a new one. (!7-32)
Inspect the swingarm and rear axle for scratches, wear or
damage. If any damages are found, replace them with a new
one. (!7-56)
Inspect the front and rear shock absorbers for oil leakage or
damage. If any damages are found, replace them with a new
one. (!7-31 and -53)

2-19

2-20

PERIODIC MAINTENANCE

CHASSIS BOLTS AND NUTS
Tighten initially at 1 month and every 3 months thereafter.
Check that all chassis nuts and bolts are tightened to their specified torque. (Refer to page 2-21 and 2-22 for
the locations of the following nuts and bolts.)
Item

kgf-m
2.3
2.3
4.9
6.5
6.5
13.8
5.0
2.9

lb-ft
16.5
16.5
35.5
47.0
47.0
99.9
36.0
21.0

6.0

43.5

29
29
6
26
16
10
23
23
26
55
78
60
85
11
60
11
60
65
65

2.9
2.9
0.6
2.6
1.6
1.0
2.3
2.3
2.6
5.5
7.8
6.0
8.5
1.1
6.0
1.1
6.0
6.5
6.5

21.0
21.0
4.4
19.0
11.6
7.0
16.5
16.5
19.0
40.0
55.0
43.5
61.5
8.0
43.5
8.0
43.5
47.0
47.0

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0
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R

Handlebar clamp bolt
Steering shaft holder bolt
Steering shaft nut
Wishbone arm pivot bolt/nut (Upper and lower)
Wheel hub nut (Front)
Wheel hub nut (Rear)
Wheel set nut (Front and rear)
Steering knuckle nut (Upper and lower)
Front shock absorber mounting bolt/nut (Upper and
lower)
Tie rod end nut
Tie rod lock nut
Front brake air bleeder valve
Front brake caliper mounting bolt
Front brake pipe nut (Upper and lower)
Front brake master cylinder mounting bolt
Front brake hose union bolt (Upper and lower)
Front brake disc plate mounting bolt
Footrest bolt (M8)
Footrest bolt (M10)
Rear shock absorber mounting bolt/nut (Upper)
Rear shock absorber mounting bolt/nut (Lower)
Swingarm pivot bolt/nut
Rear brake cam lever bolt/nut
Rear brake panel mounting nut
Rear brake pedal mounting bolt
Rear axle housing set bolt/nut (RH)
Rear axle housing set bolt/nut (LH)
Rear axle housing/final gear case bolt

1
2
3
4
5
6
7
8
9

N•m
23
23
49
65
65
138
50
29

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PERIODIC MAINTENANCE
2-21

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2-22
PERIODIC MAINTENANCE

PERIODIC MAINTENANCE

2-23

GENERAL LUBRICATION
Lubricate initially at 1 month and every 3 months
thereafter.

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Proper lubrication is important for smooth operation and long life of each working part of the vehicle.
Major lubrication points are indicated below.

1 Brake lever holder

5 Brake cam

&)Grease

2 Throttle lever and cable

6 Brake cable

*)Motor oil

3 Steering shaft holder

7 Starter cable

4 Brake pedal and cable

8 Gearshift shaft

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
vehicle has been operated under wet or rainy conditions.

2-24

PERIODIC MAINTENANCE

COMPRESSION PRESSURE CHECK
The compression pressure reading of a cylinder is a good indicator of its internal condition.
The decision to overhaul the cylinder is often based on the results of a compression test. Periodic maintenance records kept at your dealership shoud include compression readings for each maintenance service.
% Compression pressure:
Standard: 1 400 kPa (14.0 kgf/cm†, 199 psi)
Service Limit: 1 200 kPa (12.0 kgf/cm†, 171 psi)

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Low compression pressure can indicate any of the following conditions:
* Excessively worn cylinder walls
* Worn piston or piston rings
* Piston rings stuck in grooves
* Poor valve seating
* Ruptured or otherwise defective cylinder head gasket

NOTE:
When the compression pressure goes below specification, check the engine for conditions listed above.

COMPRESSION TEST PROCEDURE

NOTE:
* Before testing the engine for compression pressure, make
sure that the cylinder head nuts are tightened to the specified
torque values and the valves are properly adjusted.
* Warm up the engine before testing.
* Make sure that the battery is fully charged.
Test the compression pressure in the following manner:

Remove the spark plug. (!2-7)
Install the compression gauge and adaptor in the spark plug
hole. Make sure that the connection is tight.
Keep the throttle lever in the fully open position.
Press the starter button and crank the engine for a few seconds. Record the maximum gauge reading as the cylinder
compression.
$ 09915-64510: Compression gauge set
09918-02410: Adaptor or
09918-03810: Adaptor

PERIODIC MAINTENANCE

2-25

OIL PRESSURE CHECK
Check the engine oil pressure periodically. This will give a good indication of the condition of the moving
parts.
% Oil pressure:
Above 30 kPa (0.3 kgf/cm†, 4.3 psi)
Below 70kPa (0.7 kgf/cm†, 9.9 psi)

at 3 000 r/min, oil temp. at 60 C (140 F)

Low or high oil pressure can indicate any of the following conditions:

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LOW OIL PRESSURE
* Clogged oil filter
* Oil leakage from the oil passage
* Damaged O-ring
* Defective oil pump
* Combination of the above items
HIGH OIL PRESSURE
* Engine oil viscosity is too high
* Clogged oil passage
* Combination of the above items

OIL PRESSURE TEST PROCEDURE

Connect the tachometer onto the spark plug high-tension
cord.
Remove the oil plug 1.

Install the oil pressure gauge and adaptor into the main oil
gallery.
Warm up the engine as follows:
Summer: 10 minutes at 2 000 r/min
Winter: 20 minutes at 2 000 r/min
After warming up the engine, increase the engine speed to
3 000 r/min (observe the tachometer), and read the oil pressure gauge.

$ 09915-74511: Oil pressure gauge
09915-74512: Oil pressure gauge adaptor

2-26

PERIODIC MAINTENANCE

INITIAL ENGAGEMENT AND CLUTCH LOCK-UP INSPECTION
The LT-Z250 is equipped with a centrifugal type automatic
clutch.
To insure proper performance and longevity of the clutch
assemblies, it is essential that the clutches engage smoothly
and gradually. Before checking the initial engagement and
clutch lock-up, two inspection checks must be performed to thoroughly check the operation of the drive train. Perform the following:

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Check the oil level. (!2-10)
Warm up the engine.

INITIAL ENGAGEMENT INSPECTION

Connect the tachometer or the multi circuit tester onto the
spark plug high-tension cord.
Start the engine.
Shift the gear shift lever to the 1st position.
Slowly open the throttle and note the engine speed (r/min)
when the vehicle begins to move forward.
$ 09900-25008: Multi circuit tester set or
09900-26006: Tachometer
% Engagement speed: 1 700

2 100 r/min

If the engagement speed does not coincide with the standard
range, inspect the following items for any abnormalities.

* Clutch shoes ............................................... !3-40
* Clutch wheel ............................................... !3-40

CLUTCH LOCK-UP INSPECTION

Perform this inspection to determine if the clutch is engaging
fully and not slipping.
Connect a tachometer onto the spark plug high-tension code.
Start the engine.
Shift the gear shift lever to the 5th position.
Apply the front and rear brakes as firmly as possible.
Fully open the throttle for a brief period and note the maximum engine speed sustained during the test cycle.
% Lock-up speed: 3 100

3 700 r/min

"
Do not apply full power for more than 5 seconds or
damage to the clutch or engine may occur.
If the lock-up speed (r/min) does not coincide with the standard
range, inspect the following items for any abnormalities.
* Clutch shoes ............................................... !3-40
* Clutch wheel ............................................... !3-40

ENGINE

3-1

ENGINE

CONTENTS

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ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE............ 3- 2
ENGINE REMOVAL AND INSTALLATION .................................................. 3- 3
ENGINE REMOVAL................................................................................ 3- 3
ENGINE INSTALLATION ....................................................................... 3- 8
ENGINE DISASSEMBLY .............................................................................. 3-12
ENGINE TOP SIDE................................................................................. 3-12
ENGINE BOTTOM SIDE......................................................................... 3-15
ENGINE COMPONENTS INSPECTION AND SERVICE.............................. 3-23
CYLINDER HEAD COVER ..................................................................... 3-23
CYLINDER HEAD................................................................................... 3-25
CAMSHAFT ............................................................................................ 3-33
CAM CHAIN TENSION ADJUSTER ...................................................... 3-34
CAM CHAIN TENSIONER AND CAM CHAIN GUIDE ........................... 3-34
CYLINDER .............................................................................................. 3-35
PISTON AND PISTON RING .................................................................. 3-35
CONROD AND CRANKSHAFT.............................................................. 3-38
CLUTCH.................................................................................................. 3-39
TRANSMISSION..................................................................................... 3-42
GEARSHIFT FORK ................................................................................ 3-45
GENERATOR COVER............................................................................ 3-45
CLUTCH COVER.................................................................................... 3-46
CRANKCASE ......................................................................................... 3-47
CRANKSHAFT ....................................................................................... 3-50
DRIVE TRAIN ......................................................................................... 3-51
SECONDARY GEAR SHIMS ADJUSTMENT ........................................ 3-55
REASSEMBLY INFORMATION ............................................................. 3-58
ENGINE REASSEMBLY ............................................................................... 3-59
ENGINE BOTTOM SIDE......................................................................... 3-59
ENGINE TOP SIDE................................................................................. 3-70

3-2

ENGINE

ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE
The parts listed below can be removed and installed without removing the engine from the frame. Refer to
the page listed in each section for removal and installation instructions.
ENGINE LEFT SIDE
REMOVAL
3-15
3-15
3-15
3-15
3-19

INSTALLATION
3-70
3-69
3-69
3-69
3-63

PARTS

REMOVAL
3-16
3-16
3-16
3-18
3-18
3-18

INSTALLATION
3-69
3-68
3-65
3-64
3-64
3-64

PARTS
Starter motor
Cam chain tension adjuster
Cylinder head cover
Camshaft
Cylinder head
Cylinder
Piston
Cam chain

REMOVAL
3-12
3-13
3-13
3-13
3-14
3-14
3-14
3-20

INSTALLATION
3-76
3-75
3-75
3-73
3-72
3-72
3-70
3-63

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PARTS
Neutral switch
Secondary driven bevel gear
Generator cover
Starter idle gear
Generator
ENGINE RIGHT SIDE

Oil filter
Clutch cover
Clutch
Gearshift
Oil pump drive gear
Oil pump

ENGINE CENTER

ENGINE

ENGINE REMOVAL AND INSTALLATION
ENGINE REMOVAL
Before taking the engine out of the frame, wash the engine
using a steam cleaner. Engine removal is sequentially explained
in the following steps. Reinstall the engine by reversing the
removal procedure.
Drain engine oil. (!2-10)
Remove the seat. (!7-5)

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Disconnect the - battery lead wire 1.

Remove the left and right side covers 2. (!7-5)

Remove the left and right footrest mud guards 3. (!7-7)

Remove the fuel tank center cover and front fender 4.
(!7-6)

3-3

ENGINE

Turn the fuel valve to the ON position.
Disconnect the fuel and vacuum hoses.

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Remove the carburetor. (!5-7)

Disconnect the engine ground lead wire 5.

Disconnect the neutral switch lead wire coupler 6, signal
generator lead wire coupler 7 and generator lead wire coupler 8.

3-4

Remove the left footrest 9.

ENGINE

Remove the gearshift lever link 0.

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Remove the reverse lock release cable A.

Disconnect the spark plug cap.

Remove the right footrest B.

Remove the brake pedal C.

3-5

ENGINE

Loosen the muffler connecting bolt.

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Remove the exhaust pipe and gasket.

Disconnect the breather hose D.

Remove the starter motor lead wire.

3-6

Remove the rear upper engine mounting nut, bolts and
bracket E.

ENGINE

Remove the front and rear lower engine mounting nuts and
bolts.

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Disengage the secondary driven gear shaft from the universal
joint.

Remove the right front fender bracket F.
Dismount the engine to the right side.

3-7

3-8

ENGINE

ENGINE INSTALLATION
Remount the engine in the reverse order of engine removal.
Pay attention to the following points:

ITEM

ar
P

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NOTE:
* The engine mounting nuts are self-locking.
* Once the nut has been removed, it is no longer of any use. Be
sure to use new nuts, and then tighten them to the specified
torque.

A
BCD

N•m

kgf-m

lb-ft

2.3

16.5

6.6

48.0

CLUTCH RELEASE ADJUSTMENT
Temporarily install the gear shift lever.
Remove the clutch adjuster cap.
Loosen the clutch release outer guide nuts 1.
Loosen the locknut 2.
Turn the adjusting screw 3 clockwise until it stops.

ENGINE

Check that the gearshift lever plays A, up and down, are
same. If not, set the clutch release outer guide in suitable
position.
Fix the clutch release outer guide by tightening the clutch
release outer guide nuts 1.

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Loosen the locknut 2.
Tighten the adjusting screw 3 until it stops.
Loosen the adjusting screw 3 1/16 1 /8 turn.
Tighten the locknut 2 to the specified torque while holding
the adjusting screw 3.

Gearshift lever

" Locknut 2: 23 N•m (2.3 kgf-m, 16.5 lb-ft)

Apply engine oil to the O-ring and cap thread lightly.
Tighten the clutch adjuster cap to the specified torque.

" Clutch adjuster cap: 15 N•m (1.5 kgf-m, 11.0 lb-ft)

Engage the secondary driven gear shaft to the universal joint.

Install new gasket as its projections face outside.

3-9

3-10

ENGINE

Install a new exhaust pipe/muffler connector 4 into the muffler lip.
NOTE:
Exhaust gas sealer should be applied to both of the inside and
outside of the connector 4.
EXHAUST GAS SEALER: PERMATEX 1372

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Apply SUZUKI SUPER GREASE to the O-rings.
# 99000-25030: SUZUKI SUPER GREASE A ( USA)
99000-25010: SUZUKI SUPER GREASE A (Others)
Install the washer 5.

Install the brake pedal as its slit matches with the punched
mark on the shaft.
Tighten the brake pedal mounting bolt to the specified torque.

" Brake pedal mounting bolt: 11 N•m (1.1 kgf-m, 8.0 lb-ft)

Apply THREAD LOCK to the bolts and tighten each bolt to the
specified torque.
$ 99000-32050: THREAD LOCK 1342

" Footrest bolt: 10 mm: 55 N•m (5.5 kgf-m, 40.0 lb-ft)

Adjust the brake pedal play A.
% Brake pedal play A: 20

30 mm (0.8 1 .2 in)

ENGINE

Install the reverse gearshift arm.
% Reverse gearshift arm angle B: 20

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Install the gearshift lever.
% Gearshift arm angle C: 35

Adjust the gearshift lever height D.

% Gearshift lever height D: 0 10 mm (0 0 .4 in)

Left

Right

Position the carburetor clamps as shown in the illustration.

Engine side

After installing the engine, route the wire harness, cables and
hoses properly. (!9-11 to -14)
Check the followings.
* Engine oil !2-10
* Engine idle speed !2-9
* Throttle cable play !2-9

Left

Right

45ß

Air cleaner side

3-11

3-12

ENGINE

ENGINE DISASSEMBLY
ENGINE TOP SIDE
SPARK PLUG
Remove the spark plug.

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& 09930-10121: Spark plug wrench set

STARTER MOTOR
Remove the starter motor.

Remove the valve timing inspection plug 1 and generator
cover cap 2.

Turn the crankshaft until the TDC line A on the generator
rotor aligns with the index mark B on the crankcase.

ENGINE

CAM CHAIN TENSION ADJUSTER
Remove the spring holder bolt 1, pin and spring.

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Remove the cam chain tension adjuster.

CYLINDER HEAD COVER
Remove the cylinder head cover.

CAMSHAFT
Remove the camshaft end cap 1.
Flatten the lock washer and remove the camshaft sprocket
bolts.

Remove the dowel pins.
Remove the camshaft 2 and camshaft sprocket 3.
'
Do not drop the cam chain 4 into the crankcase.

3-13

3-14

ENGINE

Remove the C-ring 5.
'
Do not drop the C-ring 5 into the crankcase.

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CYLINDER HEAD
Remove the cylinder head nuts (M6) 1.
Loosen the cylinder base nuts (M6) 2.

Remove the cylinder head nuts (M8) diagonally.
Remove the cylinder head.

NOTE:
If the cylinder head does not come off, lightly tap on the finless
portion of it with a plastic hammer.

CYLINDER
Remove the dowel pins, cylinder head gasket and cam chain
guide 1.
Remove the cylinder base nuts (M6).
Remove the cylinder.
NOTE:
* Be careful not to drop the dowel pins into the crankcase.
* If the cylinder does not come off, lightly tap on the finless portion of it with a plastic hammer.
PISTON
Remove the piston pin circlip 1.
Remove the piston pin and piston.
NOTE:
Place a rag under the piston so as not to drop the piston pin circlip into the crankcase.
Remove the cylinder gasket and dowel pins.

ENGINE

ENGINE BOTTOM SIDE
NEUTRAL SWITCH
Remove the neutral switch 1.
Remove the switch contacts 2 and springs.

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SECONDARY DRIVEN BEVEL GEAR
Remove the secondary driven bevel gear cover.

Remove the dowell pins and secondary driven bevel gear
assembly 1.

GENERATOR COVER
Remove the generator cover and reverse lock release cable
holder 1.

STARTER IDLE GEAR
Remove the dowel pins and gasket.
Remove the starter idle gear with its shaft and spacer.

3-15

3-16

ENGINE

OIL FILTER
Remove the oil filter cover.
Remove the oil filter and O-ring 1.

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CLUTCH COVER
Remove the clutch cover.

CLUTCH

Remove the dowel pins and gasket.
Remove the clutch release ball assembly 1, inner ball guide
2, washer 3 and clutch release arm 4.

NOTE:
Slightly loosen the clutch spring bolts with holding the clutch
shoe nut to facilitate later disassembly.

While holding the generator rotor with the special tool, remove
the clutch shoe nut.
& 09930-44520: Rotor holder
'
Clutch shoe nut has left-hand threads.
Remove the clutch shoes 1 and washer.

ENGINE

Remove the clutch wheel assembly 1.

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Remove the clutch bolts.
Remove the clutch release plate 1 and springs.

Using a chisel, unlock the nut.

Remove the clutch sleeve hub nut with the special tool.

& 09920-53730: Clutch sleeve hub holder

Remove the washer 2 and primary driven gear assembly 3.

3-17

3-18

ENGINE

GEARSHIFT
Remove the gearshift arm 1.

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Remove the shift cam shaft assembly 2.

Remove the gearshift cam plate 3 and stopper 4.

OIL PUMP DRIVE GEAR
Remove the oil pump drive gear 1 and pin 2.

OIL PUMP
Remove the E-ring.
Remove the oil pump driven gear 1.

ENGINE

Remove the pin 2 and washer 3.
Remove the oil pump.

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GENERATOR
Remove the generator rotor nut with the special tool.
& 09930-44520: Rotor holder

Install the special tool to the crankshaft end.

& 09930-31921: Rotor remover attachment

Remove the generator rotor with the special tool.

& 09930-35010: Rotor remover

Remove the key 1.
Remove the starter driven gear 2.

3-19

3-20

ENGINE

CAM CHAIN
Remove the cam chain.

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CRANKCASE
Remove the left crankcase bolts.

Remove the right crankcase bolts.

Separate the crankcase with the special tool.

NOTE:
* The crankcase separator arms should be parallel with the end
face of the crankcase.
* The crankshaft must remain in the left crankcase half.
& 09920-13120: Crankcase separator

OIL SUMP FILTER
Remove the dowel pins.
Remove the oil sump filter 1.

ENGINE

DRIVE TRAIN/GEARSHIFT CAM
Remove the reverse idle gear assembly 1.

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Remove the gearshift cam 2
Remove the shafts 3 and forks 4.

Remove the shift cam lock shaft 5.

Remove the washers, reverse driven gear 6 and reverse dog
7.

CRANKSHAFT
Remove the crankshaft with the special tool.
& 09920-13120: Crankcase separator

3-21

3-22

ENGINE

DRIVE BEVEL GEAR
Using a chisel, unlock the nut.

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Fit the special tool onto the driveshaft.
& 09930-73150: Output shaft holder

Loosen the secondary drive bevel gear and nut by holding the
special tool with a vise.

Remove the secondary drive bevel gear and driveshaft
assembly, countershaft assembly.

ENGINE

ENGINE COMPONENTS INSPECTION AND SERVICE
CYLINDER HEAD COVER
DISASSEMBLY
'
Be sure to identify each removed part as to its location, and lay the parts out in groups designated as
Exhaust , Intake , so that each will be restored to
the original location during assembly.

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Remove the valve inspection caps 1.
Remove the rocker arm shaft bolts 2.

Remove the rocker arm shafts 3.
Remove the rocker arms 4 and wave washers 5.

CYLINDER HEAD COVER DISTORTION
After removing sealant from the fitting surface of the cylinder
head cover, place the cylinder head cover on a surface plate
and check for distortion with a thickness gauge.

% Cylinder head cover distortion
Service Limit: 0.05 mm (0.002 in)
& 09900-20803: Thickness gauge

If the distortion exceeds the limit, replace the cylinder head
cover.
ROCKER ARM SHAFT O.D.
Measure diameter of rocker arm shaft.

% Rocker arm shaft O.D. (IN & EX)
Standard: 11.977 11.995 mm (0.4715 0 .4722 in)
& 09900-20205: Micrometer (0

25 mm)

3-23

3-24

ENGINE

ROCKER ARM I.D.
When checking the rocker arm, the inside diameter of the rocker
arm and wear of the camshaft contacting surface should be
checked.
% Rocker arm I.D.
Standard: 12.000 1 2.018 mm (0.4724 0 .4731 in)
& 09900-20605: Dial calipers

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REASSEMBLY
Reassemble the cylinder head cover in the reverse order of disassembly. Pay attention to the following points:
Install new O-rings 1 to the rocker arm shafts.
Apply engine oil to the rocker arms and shafts.
Install the rocker arms, wave washers and shafts to the cylinder head cover.

Tighten the rocker arm shaft bolts to the specified torque.
" Rocker arm shaft bolt: 9 N•m (0.9 kgf-m, 6.5 lb-ft)
'

Install the gasket washers to prevent oil leakage.

Install new O-rings to the valve inspection caps.
Apply SUZUKI SUPER GREASE to the O-rings.

# 09900-25030: SUZUKI SUPER GREASE A ( USA)
09900-25010: SUZUKI SUPER GREASE A (Others)

ENGINE

CYLINDER HEAD
DISASSEMBLY
Remove the intake pipe 1.
Remove the cam chain tensioner 2.
Cam chain tentioner inspection (!3-34)

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Compress the valve spring and remove the valve cotters from
the valve stem with the special tools.
& 09916-14510: Valve spring compressor
09916-14910: Attachment
09916-84511: Tweezers

Remove the valve spring retainer and valve spring.
Remove the valve from the other side.

Remove the valve stem seal with long-nose pliers.
Remove the valve spring seat.

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

CYLINDER HEAD DISTORTION
Decarbonize the combustion chamber.
Check the gasket surface of the cylinder head for distortion
using a straightedge and thickness gauge. Take clearance
readings at several places. If any clearance reading exceeds
the service limit, replace the cylinder head with a new one.
% Cylinder head distortion
Service Limit: 0.05 mm (0.002 in)
& 09900-20803: Thickness gauge

3-25

3-26

ENGINE

VALVE STEM RUNOUT
Support the valve with the V-blocks and measure the valve stem
runout with the dial gauge, as shown. If the runout exceeds the
service limit, replace the valve with a new one.
% Valve stem runout
Service Limit: 0.05 mm (0.002 in)
& 09900-20701: Magnetic stand
09900-20607: Dial gauge (1/100 mm)
09900-21304: V-block

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VALVE HEAD RADIAL RUNOUT
Support the valve with the V-blocks and measure the valve head
radial runout with the dial gauge, as shown. If the runout
exceeds the service limit, replace the valve with a new one.
% Valve head radial runout
Service Limit: 0.03 mm (0.001 in)

& 09900-20701: Magnetic stand
09900-20607: Dial gauge (1/100 mm)
09900-21304: V-block

VALVE FACE WEAR
Visually inspect each valve face for wear or damage. If any
abnormal wear is found, replace the respective valve with a new
one. Measure the valve head thickness T. If the valve head
thickness is not within the specified value, replace the value with
a new one.

% Valve head thickness T
Service Limit: 0.5 mm (0.02 in)
& 09900-20101: Vernier calipers

VALVE STEM DEFLECTION
Lift the valve about 10 mm (0.39 in) from the valve seat. Measure the valve stem deflection in two directions, X and Y , perpendicular to each other, by positioning the dial gauge as
shown. If the deflection exceeds the service limit, determine
whether the valve or the guide should be replaced with a new
one.
% Valve stem deflection (IN & EX)
Service Limit: 0.35 mm (0.14 in)
& 09900-20607: Dial gauge (1/100 mm)
09900-20701: Magnetic stand

ENGINE

VALVE STEM WEAR
Measure the valve stem outside diameter with the micrometer. If
the outside diameter is not within the specified value, replace
the valve with a new one. If the valve stem outside diameter is
within specification, but the valve stem deflection is not, replace
the valve guide with a new one. After replacing the valve or
valve guide, check the deflection and.
% Valve stem O.D.
Standard (IN) : 5.475 5.4 90 mm (0.2156 0.2 161 in)
(EX) : 5.455 5.4 70 mm (0.2148 0.2 154 in)
25 mm)

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& 09900-20205: Micrometer (0

VALVE GUIDE SERVICING
Drive the valve guide out toward the intake or exhaust rocker
arm side with the valve guide remover.
& 09916-44910: Valve guide remover/installer

NOTE:
* Discard the removed valve guide.
* Only oversized valve guides are available as replacement
parts. (Part No. 11115-05270)

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

& 09916-34561: Valve guide reamer (11.3 mm)
09916-34542: Reamer handle

Install a ring onto each valve guide. Be sure to use new rings.
Oil the stem hole of each valve guide and drive the guide into
the guide hole with the valve guide installer.

& 09916-44910: Valve guide remover/installer
'

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

3-27

3-28

ENGINE

After fitting all valve guides, re-finish their guiding bores with
the valve guide reamer. Be sure to clean and oil the guide
after reaming.
& 09916-34550: Valve guide reamer (5.5 mm)
09916-34542: Reamer handle
NOTE:
Insert the reamer from the combustion chamber and always turn
the reamer handle clockwise.

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VALVE SEAT WIDTH
Coat the valve seat with prussian blue uniformly. Install the
valve and attach the valve lapper onto it. Tap the coated seat
with the valve face in a rotating manner, in order to obtain a
clear impression of the seating contact.
& 09916-10911: Valve lapper set

The ring-like dye impression left on the valve face must be
continuous, without any breaks. In addition, the width of the
dye ring, which is the valve seat width, must be within the following specification.
% Valve seat width W
Standard: 0.88 1.08 mm (0.035

0.043 in)

If the valve seat is out of specification, re-cut the seat.

VALVE SEAT SERVICE
The valve seats for intake and exhaust valves are machined to
two different angles. The seat contact surface is cut at 45 .

15
45

INTAKE
N-212
N-608

EXHAUST
N-121
N-122

& 09916-21111: Valve seat cutter set
09916-24900: Valve seat cutter set
09916-22480: Solid pilot (N-140-5.5)
09916-24450: Solid pilot (N-100-5.52)
09916-24935: Valve seat cutter (N-608)
'
The valve seat contact area must be inspected after
each cut.

Valve seat

ENGINE

When installing the solid pilot, rotate it slightly. Seat the pilot
snugly. Install the 45 cutter, attachment and T-handle.

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INITIAL SEAT CUT
Descale and clean up the seat with the 45 cutter. Rotate the
cutter one or two turns.
Measure the valve seat width W after every cut.

If the valve seat is pitted or burned, use the 45 cutter to condition the seat some more.

NOTE:
Cut only the minimum amount necessary from the seat to prevent the possibility of the valve stem becoming too close to the
camshaft.

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

Too high or too wide contact surface
on the valve

3-29

3-30

ENGINE

FINAL SEAT CUT
If the contact area W is too low or too narrow, use the 45 cutter to raise and widen the contact area.

Too low or too narrow contact surface
on the valve

NOTE:
After cutting the 15 angle, it is possible that the valve seat (45 )
is too narrow. If so, re-cut the valve seat to the correct width.

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

Do not use lapping compound after the final cut is
made. The finished valve seat should have a velvety
smooth finish but not a highly polished or shiny finish. This will provide a soft surface for the final seating of the valve which will occur during the first few
seconds of engine operation.

NOTE:
After servicing the valve seats, be sure to check the valve clearance after the cylinder head has been reinstalled. (!2-5)

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

Always use extreme caution when handling gasoline.

VALVE STEM END CONDITION
Inspect the valve stem end face for pitting and wear. If pitting or
wear of the stem end face are present, the valve stem end may
be resurfaced, providing that the length 1 will not be reduced to
less than the service limit. If this length becomes less than the
service limit, the valve must be replaced.
% Valve stem end length
Service Limit: 2.5 mm (0.10 in)

ENGINE

3-31

VALVE SPRING
The force of the coil spring keeps the valve seat tight. Weakened spring result in reduced engine power output, and often
account for the chattering noise coming from the valve mechanism.
Check the valve springs for proper strength by measuring their
free length and also by the force required to compress them. If
the spring length is less than the service limit or if the force
required to compress the valve spring is not within specification,
replace both the inner and outer springs as a set.
256

294 N

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% Valve spring free length (IN & EX)
Service Limit: 43.0 mm (1.69 in)

% Valve spring tension (IN & EX)
Standard: 256 29 4 N/36.6 mm
(26.1 30.0 kgf/36.6 mm,
57.5 6 6.1 lbs/1.44 in)

36.6 mm

& 09900-20101: Vernier calipers

REASSEMBLY
Install each valve spring seat.
Apply engine oil to each oil seal and press-fit them into position.
'

Do not reuse the oil seal.

Insert the valves, with their stems coated with molybdenum oil
solution all around and along the full stem length without any
break.

) MOLYBDENUM OIL SOLUTION
'

When inserting each valve into the valve guides, make
sure not to damage the lip of the oil seal.

Install the valve spring with the smaller pitch portion A facing
the cylinder head.
A Smaller pitch portion.
B Larger pitch portion.
Cylinder head

3-32

ENGINE

Put on the valve spring retainer, and using the valve lifter,
press down the springs, fit the cotter halves to the stem end,
and release the lifter to allow the cotter 1 to wedge in
between retainer and stem. Be sure that the rounded lip 2 of
the cotter fits snugly into the groove 3 in the stem end.
& 09916-14510: Valve spring compressor
09916-14910: Valve spring compressor attachment
09916-84511: Tweezers
'

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

INTAKE PIPE
When installing the intake pipe, apply SUZUKI SUPER
GREASE to the O-ring.
# 99000-25030: SUZUKI SUPER GREASE A ( USA)
99000-25010: SUZUKI SUPER GREASE A (Others)
'

Use the new O-ring to prevent sucking air from the
joint.

NOTE:
Make sure that the protrusion A faces upward.

Install the intake pipe 1 and cam chain tensioner 2.
Tighten the cam chain tensioner mounting bolt to the specified torque.
" Cam chain tensioner mounting bolt:
13 N•m (1.3 kgf-m, 9.5 lb-ft)

ENGINE

CAMSHAFT
The camshaft should be checked for wear and also for runout of
cams and journals if the engine has been noted to produce
abnormal noise or vibration or to lack output power. Any of these
malconditions could be caused by a worn camshaft.
CAMSHAFT CAM WEAR
Worn-down cams are often the cause of mistimed valve operation resulting in reduced power output.
Measure the cam height H with the micrometer. If the cams are
worn to the service limit, replace the camshaft with a new one.

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% Cam height H
Service Limit (IN) : 33.480 mm (1.3181 in)
(EX) : 32.690 mm (1.2870 in)
& 09900-20202: Micrometer (25

50 mm)

CAMSHAFT JOURNAL WEAR
Determine whether each journal is worn down to the limit or not
by measuring camshaft journal oil clearance with the camshaft
installed. Use the plastigauge to read the clearance, which is
specified as follows:
% Camshaft journal oil clearance
Service Limit: 0.150 mm (0.0059 in)
& 09900-22302: Plastigauge

NOTE:
To properly measure the oil clearance with plastigauge, all gasket material must be removed from fitting surfaces of cylinder
head and cover. Do not apply SUZUKI BOND until after the oil
clearance has been determined.

Tighten the cylinder head cover bolts evenly and diagonally to
the specified torque.
" Cylinder head cover bolt: 10 N•m (1.0 kgf-m, 7.3 lb-ft)
NOTE:
Do not rotate the camshafts with the plastigauge in place.

Remove the cylinder head cover, read the width of the compressed plastigauge with envelope scale. This measurement
should be taken at the widest part of the compressed plastigauge.

3-33

3-34

ENGINE

If the camshaft journal oil clearance measured exceeds the limit,
measure the outside diameter of camshaft.
Replace either the cylinder head set or the camshaft if the clearance is incorrect.
% Camshaft journal O.D.
Standard: 21.959 21.976 mm
(0.8645 0 .8652 in)
& 09900-20205: Micrometer (0 2 5 mm)

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CAMSHAFT RUNOUT
Measure the camshaft runout with the special tools. If the runout
exceeds the service limit, replace the camshaft with a new one.
% Camshaft runout (IN & EX)
Service Limit: 0.10 mm (0.004 in)

& 09900-20607: Dial gauge (1/100, 10 mm)
09900-20701: Magnetic stand
09900-21304: V-block (100 mm)

CAM CHAIN TENSION ADJUSTER

Check that the push rod slides smoothly with unlocking the
ratchet mechanism 1. If any stickiness is noted or ratchet
mechanism is faulty, replace the cam chain tension adjuster with
a new one.

CAM CHAIN TENSIONER AND CAM CHAIN
GUIDE

Check the contacting surface of the cam chain tensioner/guide
for wear and damage. If it is worn or damaged, replace it with a
new one.

ENGINE

3-35

CYLINDER
CYLINDER DISTORTION
Check the gasket surface of the cylinder for distortion with a
straightedge and the thickness gauge, taking a clearance reading at several places as indicated. If any clearance reading
exceeds the service limit, replace the cylinder with a new one.
% Cylinder distortion
Service Limit: 0.05 mm (0.002 in)
& 09900-20803: Thickness gauge

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CYLINDER BORE
Inspect the cylinder wall for any scratches, nicks or other damage. Measure the cylinder bore diameter at six places.
% Cylinder bore
Service Limit: 66.090 mm (2.6020 in)
& 09900-20508: Cylinder gauge set

PISTON AND PISTON RING

PISTON DIAMETER
Measure the piston diameter with the micrometer at 18 mm
(0.71 in) from the skirt end.
If the piston diameter is less than the service limit, replace the
piston with a new one.

% Piston diameter
Service Limit: 65.880 mm (2.5937 in)
& 09900-20203: Micrometer (50

75 mm)

PISTON TO CYLINDER CLEARANCE
As a result of the aforesaid measurement, if the piston to cylinder clearance exceeds the following limit, overhaul the cylinder
and use an oversize piston, or replace both of the cylinder and
piston.
% Piston to cylinder clearance
Service Limit: 0.12 mm (0.0047 in)
Piston oversize: 0.5

18 mm (0.71 in)

3-36

ENGINE

PISTON RING TO GROOVE CLEARANCE
Measure the side clearances of the 1st and 2nd piston rings with
the thickness gauge. If any clearance reading exceeds the service limit, replace both the piston and piston rings.
% Piston ring to groove clearance
Service Limit (1st) : 0.18 mm (0.0071 in)
(2nd): 0.15 mm (0.0059 in)

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% Piston ring groove width
Standard (1st) : 1.01 1 .03 mm (0.0398 0 .0406 in)
(2nd): 1.21 1.23 mm (0.0476 0.0 484 in)
(Oil) : 2.01 2 .03 mm (0.0791 0 .0799 in)
% Piston ring thickness
Standard (1st) : 0.97 0.99 mm
(0.038 0 .039 in)
(2nd): 1.17 1.19 mm
(0.046 0 .047 in)

& 09900-20803: Thickness gauge
09900-20205: Micrometer (0 2 5 mm)

PISTON RING FREE END GAP AND PISTON RING END GAP
At first measure the piston ring free end gap with the vernier calipers and then fit the piston ring squarely into the cylinder and
measure the piston ring end gap with the thickness gauge.
If any measurement exceeds the service limit, replace the piston
ring with a new one.

% Piston ring free end gap
Service Limit (1st) : 7.0 mm (0.28 in)
(2nd): 6.1 mm (0.24 in)

% Piston ring end gap
Service Limit (1st) : 0.50 mm (0.020 in)
(2nd): 0.50 mm (0.020 in)
& 09900-20101: Vernier calipers
09900-20803: Thickness gauge

ENGINE

3-37

Oversize piston ring
The following oversize piston rings are used. They bear the following identification numbers.
SIZE
0.5 mm O.S.

1st

2nd

0.5 mm O.S.

Oversize oil ring
The following oversize oil ring is available as optional parts.
They bear the following identification mark.
COLOR
NIL
Painted Red

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SIZE
STD
0.5 mm O.S.

Oversize side rail
Just measure outside diameter to identify the side rail as there is
no mark or numbers on it.

PISTON PIN AND PIN BORE
Measure the piston pin bore diameter with the small bore gauge.
If the diameter exceeds the service limit, replace the piston with
a new one.
% Piston pin bore I.D.
Service Limit: 16.030 mm (0.6311 in)

& 09900-20602: Dial gauge (1/1 000 mm, 1 mm)
09900-22401: Small bore gauge (10 1 8 mm)

Measure the piston pin outside diameter at three positions with
the micrometer. If any measurement exceeds the service limit,
replace the piston pin with a new one.
% Piston pin O.D.
Service Limit: 15.980 mm (0.6291 in)
& 09900-20205: Micrometer (0

25 mm)

Paint

Oil ring spacer

3-38

ENGINE

CONROD AND CRANKSHAFT
CONROD SMALL END I.D.
Measure the conrod small end inside diameter with the small
bore gauge. 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: 16.040 mm (0.6315 in)
& 09900-20605: Dial calipers (10 34 mm)
09900-22401: Small bore gauge (10 1 8 mm)

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CONROD DEFLECTION
Wear of the conrod big end can be estimated by checking the
movement of the conrod small end. This method can also be
used to check the extent of wear on the parts of the conrod big
end.
% Conrod deflection
Service Limit: 3.0 mm (0.12 in)

& 09900-20701: Magnetic stand
09900-20607: Dial gauge (1/100 mm)
09900-21304: V-block

CONROD BIG END SIDE CLEARANCE
Slide the conrod big end to one side and measure the side clearance with the thickness gauge. If the clearance exceeds the service limit, replace the crankshaft assembly with a new one or
bring the deflection and the side clearance within the service
limit by replacing the worn parts (conrod, big end bearing, crank
pin, etc.) with new ones.
% Conrod big end side clearance
Service Limit: 1.0 mm (0.04 in)

& 09900-20803: Thickness gauge

CRANKSHAFT RUNOUT
Support the crankshaft with the V-blocks and measure the
crankshaft runout with the dial gauge. If the runout exceeds the
service limit, correct or replace the crankshaft with a new one.
% Crankshaft runout
Service Limit: 0.08 mm (0.003 in)
& 09900-20607: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
09910-21304: V-block set (100 mm)

ENGINE

CLUTCH
CLUTCH DRIVE PLATES
NOTE:
Wipe off engine oil from the clutch drive plates with a clean rag.
Measure the thickness of drive plates with a vernier calipers.
If each drive plate is not within the standard range, replace it
with a new one.
% Drive plate thickness
Standard: 2.7 2.9 mm (0.106 0. 114 in)

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& 09900-20101: Vernier calipers
Measure the claw width of drive plates with a vernier calipers.
Replace the drive plates found to have worn down to the limit.
% Drive plate claw width
Service Limit: 11.0 mm (0.43 in)
& 09900-20101: Vernier calipers

CLUTCH DRIVEN PLATES

NOTE:
Wipe off engine oil from the clutch driven plates with a clean rag.

Measure each driven plate for distortion with a thickness
gauge and surface plate.
Replace driven plates which exceed the limit.
% Driven plate distortion
Service Limit: 0.10 mm (0.004 in)

& 09900-20803: Thickness gauge

CLUTCH SPRING
Measure the free length of each coil spring with a vernier calipers, and compare the length with the specified limit.
Replace all the springs if any spring is not within the limit.
% Clutch spring free length
Service Limit: 27.5 mm (1.08 in)
& 09900-20101: Vernier calipers

3-39

3-40

ENGINE

CLUTCH SHOES
Inspect the clutch shoes for chips, cracks, uneven wear, and
heat discoloration. Also, check the depth of the grooves on the
clutch shoes. If there is no groove at any part of the shoes,
replace the shoes as a set.
NOTE:
The clutch shoes must always be changed as a set.

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ONE-WAY CLUTCH
Rotate the inner race by hand to inspect that the inner race turns
in one direction only and never turns in the opposite direction. If
the inner race turns in both directions or is locked, replace the
one-way clutch with a new one.

CLUTCH WHEEL
Remove the inner race and one-way clutch.
Inspect the condition of the clutch wheel inner surface for scuffs,
scratches, cracks or uneven wear. If any damages are found,
replace the clutch wheel with a new one.

STARTER CLUTCH
Remove the starter clutch securing bolts by holding the rotor
with the special tool.
& 09930-44520: Rotor holder

Install the starter clutch in the proper direction.
NOTE:
* When installing the starter clutch onto the rotor, make sure that
the flange side A of the one way clutch faces to the rotor.
* The arrow mark B must face to the engine side.
Apply engine oil to the starter clutch.

ENGINE

Apply THREAD LOCK SUPER to the bolts, and then tighten
them to the specified torque with a offset wrench.
" Starter clutch bolt: 26 N•m (2.6 kgf-m, 19.0 lb-ft)
* 99000-32030: THREAD LOCK SUPER 1303
& 09930-44520: Rotor holder

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Install the starter driven gear to the starter clutch.
Check that the starter driven gear turns only in counter clockwise.
If there is anything unusual, replace the one way clutch.

Check the starter driven gear bearing. If there is anything
unusual, replace the bearing.
Remove the bearing with the special tool.

& 09913-70210: Bearing installer set

Install the bearing with the special tool.

& 09913-70210: Bearing installer set

3-41

3-42

ENGINE

TRANSMISSION
DISASSEMBLY
Insert the special tool between the 2nd drive gear and 4th
drive gear.
Remove the 2nd drive gear by a hydraulic press.
& 09950-81910: Remover

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Disassemble the transmission as shown.

1 Reverse driven gear
2 Reverse gear dog
3 1st driven gear
4 5th driven gear
5 3rd driven gear
6 4th driven gear
7 2nd driven gear
8 Driveshaft
9 Countershaft
0 5th drive gear
A 3rd drive gear
B 4th drive gear
C 2nd drive gear
D Reverse idle gear
E Reverse idle shaft

ENGINE

REASSEMBLY
Assemble the transfer in the reverse order of disassembly. Pay
attention to the following points:
NOTE:
* Always use new snap rings.
* Before installing the gears, coat lightly engine oil to the shafts
and gears.
'

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* Never reuse a snap ring. After a snap ring has been
removed from a shaft, it should be discarded and a
new snap ring must be installed.
* When installing a new snap ring, care must be taken
not to expand the end gap larger than required to slip
the snap ring over the shaft.
* After installing a snap ring, always ensure that it is
completely seated in its groove and securely fitted.

When installing a new snap ring, pay attention to the direction
of the snap ring. Fit it to the side where the thrust is as shown
in the figure.

Thrust

Sharp edge

Install the clutch sleeve hub nut 1 onto the right end of the
countershaft.

Apply THREAD LOCK SUPER to the internal face of the 2nd
drive gear.
Install the 2nd drive gear by a hydraulic press and special
tool.
* 99000-32030: THREAD LOCK SUPER 1303
& 09913-70210: Bearing installer set
NOTE:
After installing the 2nd drive gear, check the 4th drive gear spins
smoothly with your fingers.

3-43

ENGINE

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3-44

When installing the bushings, align the shaft hole with the
bushing hole.

ENGINE

GEARSHIFT FORK
SHIFT FORK TO GROOVE CLEARANCE
Clearance for each gearshift fork plays an important role in the
smoothness and positiveness of the shifting process.
Measure the gearshift fork clearance in the groove of its respective gear with the thickness gauge.
If the clearance exceeds specification, replace the fork, its
respective gear, or both.

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% Shift fork to groove clearance
Standard: 0.10 0.30 mm (0.004 0.012 in)
Service Limit: 0.50 mm (0.020 in)
& 09900-20803: Thickness gauge
09900-20101: Vernier calipers

% Shift fork groove width
Standard: 4.50 4.60 mm (0.177

0.173 in)

% Shift fork thickness
Standard: 4.30 4.40 mm (0.169

0.181 in)

GENERATOR COVER
DISASSEMBLY
Remove the generator stator.
REASSEMBLY
Install the generator stator.
Tighten the generator stator bolts in the specified torque.
" Generator stator bolt: 7 N•m (0.7 kgf-m, 5.0 lb-ft)

3-45

3-46

ENGINE

CLUTCH COVER
DISASSEMBLY
Remove the clutch release outer guide 1.

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Remove the bearing with the special tool.
& 09921-20240: Bearing remover set

NOTE:
If there is no abnormal noise, the bearing removal is not necessary.

INSPECTION
Rotate the balls by hand to inspect for an abnormal noise and a
smooth rotation. Replace the clutch release ball assembly if
there is anything unusual.

REASSEMBLY
Install the bearing with the special tool.
& 09913-70210: Bearing installer set

NOTE:
The bearing seal must face the clutch cover.

Install the clutch release outer guide 1.

ENGINE

CRANKCASE

Play

BEARING INSPECTION
Rotate the bearing inner race by finger to inspect for abnormal
play, noise and smooth rotation while the bearings are in the
crankcase.
Replace the bearing in the following procedure if there is anything unusual.

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BEARING REMOVAL
Remove the bearing retainers.

Remove the bearings with the special tools.
Use proper bars for the drive bevel gear bearing removal.
& 09921-20240: Bearing remover set
09923-74510: Bearing remover
09930-30104: Sliding shaft
'

The removed bearings should be replaced with new
ones.

Play

3-47

3-48

ENGINE

BEARING INSTALLATION
Install the bearings with the special tool.

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& 09913-70210: Bearing installer set

Install the bearing retainers.

NOTE:
When installing the bearing retainers, apply a small quantity of
THREAD LOCK to the screws.

$ 09900-32050: THREAD LOCK 1342

OIL SEAL REMOVAL AND INSTALLATION
Remove the oil seal.
'
Replace the removed oil seal with a new one.

ENGINE

Apply SUZUKI SUPER GREASE to the oil seal.
# 99000-25030: SUZUKI SUPER GREASE A ( USA)
99000-25010: SUZUKI SUPER GREASE A ( Others)
NOTE:
When installing the oil seal, the stamped mark on the oil seal
must face outside.

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Install the oil seal with the special tool.
& 09913-70210: Bearing installer set

ENGINE MOUNTING RUBBER AND INSTALLATION
Remove and install the engine mounting rubber with the special tool.

& 09913-70210: Bearing installer set

OIL JET INSTALLATION
Install the new oil jet in the proper direction.
Inside

3-49

3-50

ENGINE

CRANKSHAFT

1 Crankshaft (R)
2 Crank pin
3 Bearing
4 Conrod
5 Crankshaft (L)

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DISASSEMBLY

REASSEMBLY
Determine the width between the webs referring to the figure
when rebuilding the crankshaft.

% Crank web to web width
Standard: 53.0 – 0.1mm (2.087 – 0.004 in)

ENGINE

DRIVE TRAIN

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SECONDARY BEVEL GEARS CONSTRUCTION

1 Bearing
2 Shim
3 Secondary bevel drive gear
4 Washer
5 Washer
6 Secondary bevel driven gear
7 Shim
8 Bearing
9 Secondary bevel gear shaft
0 Bearing
A Oil seal
B O-ring
C Water proof cover
D Snap ring

ITEM

A, B

N•m

kgf-m

lb-ft

100

10.0

72.5

3-51

3-52

ENGINE

SECONDARY DRIVEN BEVEL GEAR REMOVAL
The following components must be removed in the described
order before removing the secondary driven bevel gear.
NOTE:
Refer to the following pages for the details of each step.
Remove the rear wheel. (!7-11)
Remove the swingarm. (!7-56)
Remove the universal joint.
Remove the secondary driven bevel gear.

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SECONDARY DRIVEN BEVEL GEAR DISASSEMBLY
Remove the water proof cover 1 by removing the snap ring.
& 09900-06107: Snap ring pliers

Remove the oil seal 2 and bearing 3.

Using a chisel, unlock the nut.
Fit the universal joint onto the driven bevel gear shaft.
Remove the driven bevel gear shaft by holding the universal
joint with a vise.

Remove the washer 4, bevel gear 5, shim 6 and bearing
7.

ENGINE

INSPECTION
Inspect the removed parts for the following abnormalities.
* Drive and driven bevel gears damage or wear
* Improper tooth contact
* Abnormal noise of bearings
* Bearing damage or wear
* Oil seal damage or wear
SECONDARY DRIVEN BEVEL GEAR REASSEMBLY
Install the bearing.

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NOTE:
Pay attention to the direction of the bearing.

Install the shim 1, driven gear and washer 2.

Fit the universal joint onto the driven bevel gear shaft.
Tighten the driven bevel gear nut to the specified torque.

" Secondary driven bevel gear nut:
100 N•m (10.0 kgf-m, 72.5 lb-ft)
Stake the nut with a center punch.

Install the bearing.
NOTE:
Pay attention to the direction of the bearing.

3-53

3-54

ENGINE

Apply 4 5 gram of WATER RESISTANCE GREASE to the
outside of the seal lip groove.
Apply SUZUKI SUPER GREASE to the seal lip groove and
install it.
+ 99000-25160: WATER RESISTANCE GREASE
# 99000-25030: SUZUKI SUPER GREASE A ( USA)
99000-25010: SUZUKI SUPER GREASE A (Others)

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Apply SUZUKI SUPER GREASE to the O-ring and install the
water proof cover.
# 99000-25030: SUZUKI SUPER GREASE A ( USA)
99000-25010: SUZUKI SUPER GREASE A (Others)

Install the snap ring.

& 09900-06107: Snap ring pliers

ENGINE

3-55

SECONDARY GEAR SHIMS ADJUSTMENT
Remove the secondary bevel gear cover.

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Hold the bearings with the special tool.
& 09921-21910: Bearing holder

Set a dial gauge on the driven bevel gear as shown.

Measure the backlash by turning the driven bevel gear shaft in
each direction, reading the total backlash on the dial gauge. If
the backlash is not within specification, the shim must be
changed and the backlash should be re-checked until correct.
Refer to the chart at the right for appropriate shim thickness.
% Bevel gear backlash
Standard: 0.03 0.15 mm (0.001

0.006 in)

NOTE:
Adjust the backlash by referring to the chart at the right and
using the thickness of the removed shims as a guide.
Backlash
Under 0.03 mm
(0.001 in)
0.03 0.15 mm
(0.001 0.006 in)
Over 0.15 mm
(0.006 in)

Shim adjustment
Decrease shim thickness
Correct
Increase shim thickness

For driven bevel gear (

3-58)

Part No.

Shim thickness

09181-25051

0.60 mm (0.0236 in)

09181-25052

0.65 mm (0.0256 in)

09181-25053

0.70 mm (0.0276 in)

09181-25054

0.75 mm (0.0295 in)

09181-25055

0.80 mm (0.0315 in)

09181-25056

0.85 mm (0.0335 in)

09181-25057

0.90 mm (0.0354 in)

09181-25058

0.95 mm (0.0374 in)

09181-25059

1.00 mm (0.0394 in)

09181-25060

1.05 mm (0.0413 in)

09181-25061

1.10 mm (0.0433 in)

09181-25062

1.15 mm (0.0453 in)

09181-25063

1.20 mm (0.0472 in)

3-56

ENGINE

1 Incorrect (contact at tooth top)
2 Correct
3 Incorrect (contact at tooth root)

If tooth contact is found to be incorrect (examples 1 and 3),
the shim thickness between the drive bevel gear and driven
bevel gear must be changed and the tooth contact rechecked
until correct.
'

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TOOTH CONTACT
After backlash adjustment is carried out, the tooth contact must
be checked. Pay attention to the following procedures:
Remove the driven bevel gear.
Clean and degrease several teeth of the drive and driven
bevel gears.
Apply a coating of machinist s layout dye or paste to several
teeth of the driven bevel gear.
Install the driven bevel gear.
Rotate the driven bevel gear several turns in both directions.
Remove the driven bevel gear and inspect the coated teeth of
the drive bevel gear. The tooth contact pattern should be as
shown in 1, 2 and 3.
If tooth contact is found to be correct (example 2), go to the
ENGINE REASSEMBLY section on page 3-59 to complete
installation.

Make sure to check the backlash after the tooth contact has been adjusted, since it may have changed.
Adjust the tooth contact and backlash until they are
both within specification. If the correct tooth contact
cannot be maintained when adjusting the backlash,
replace the drive and driven bevel gears.
Tooth contact
Contact at tooth top 1
Contact at tooth root 3

Drive bevel gear shim adjustment Driven bevel gear shim adjustment
Increase shim thickness
Increase shim thickness
Decrease shim thickness
Decrease shim thickness

ENGINE

For drive bevel gear (
Part No.

3-58)
Shim thickness
0.25+0.25=0.50 mm (0.0197 in)

24935-19B00-025: 0.25 mm (0.0098 in)

24935-19B00-030: 0.30 mm (0.0118 in)

24935-19B00-035: 0.35 mm (0.0138 in)

Combined shim

0.25+0.30=0.55 mm (0.0217 in)
0.30+0.30=0.60 mm (0.0236 in)
0.30+0.35=0.65 mm (0.0256 in)
0.35+0.35=0.70 mm (0.0276 in)
0.25+0.25+0.25=0.75 mm (0.0295 in)
0.25+0.25+0.30=0.80 mm (0.0315 in)
0.25+0.25+0.35=0.85 mm (0.0335 in)
0.90 mm (0.0354 in)

24935-19B00-095

0.95 mm (0.0374 in)

24935-19B00-100

1.00 mm (0.0394 in)

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24935-19B00-090

1.05 mm (0.0413 in)

1.10 mm (0.0433 in)

24935-19B00-115

1.15 mm (0.0453 in)

24935-19B00-105
24935-19B00-110

3-57

3-58

ENGINE

REASSEMBLY INFORMATION

List of shims
gear side

B available for the driven bevel
Shim thickness
0.60 mm (0.0236 in)

09181-25052

0.65 mm (0.0256 in)

09181-25053

0.70 mm (0.0276 in)

09181-25054

0.75 mm (0.0295 in)

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Part No.
09181-25051

List of shims

09181-25055

0.80 mm (0.0315 in)

09181-25056

0.85 mm (0.0335 in)

09181-25057

0.90 mm (0.0354 in)

09181-25058

0.95 mm (0.0374 in)

09181-25059

1.00 mm (0.0394 in)

09181-25060

1.05 mm (0.0413 in)

09181-25061

1.10 mm (0.0433 in)

09181-25062

1.15 mm (0.0453 in)

09181-25063

1.20 mm (0.0472 in)

A available for the drive bevel gear side

Shim thickness

Part No.

0.25+0.25=0.50 mm (0.0197 in)

24935-19B00-030: 0.30 mm (0.0118 in)

24935-19B00-035: 0.35 mm (0.0138 in)

Combined shim

24935-19B00-025: 0.25 mm (0.0098 in)

0.25+0.30=0.55 mm (0.0217 in)

0.30+0.30=0.60 mm (0.0236 in)

0.30+0.35=0.65 mm (0.0256 in)
0.35+0.35=0.70 mm (0.0276 in)
0.25+0.25+0.25=0.75 mm (0.0295 in)
0.25+0.25+0.30=0.80 mm (0.0315 in)

0.25+0.25+0.35=0.85 mm (0.0335 in)

24935-19B00-090

0.90 mm (0.0354 in)

24935-19B00-095

0.95 mm (0.0374 in)

24935-19B00-100

1.00 mm (0.0394 in)

24935-19B00-105

1.05 mm (0.0413 in)

24935-19B00-110

1.10 mm (0.0433 in)

24935-19B00-115

1.15 mm (0.0453 in)

ITEM

N•m

kgf-m

lb-ft

100

10.0

72.5

ENGINE

ENGINE REASSEMBLY
Reassemble the engine in the reverse order of disassembly.
Pay special attention to the following points:
NOTE:
Apply engine oil to each running and sliding part before reassembling.

ENGINE BOTTOM SIDE

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DRIVE TRAIN
Install the driveshaft and countershaft assembly.

DRIVE BEVEL GEAR
Install the shim 1.
Install the drive bevel gear and washer 2.

Fit the special tool onto the driveshaft.

& 09930-73150: Output shaft holder

Tighten the secondary drive bevel gear nut to the specified
torque by holding the special tool with a vise.
" Secondary drive bevel gear nut:
100 N•m (10.0 kgf-m, 72.5 lb-ft)
Stake the nut with a center punch.

3-59

3-60

ENGINE

CRANKSHAFT
When mounting the crankshaft in the crankcase, it is necessary to pull its left end into the crankcase with the special tool.
NOTE:
Use proper bars.
& 09910-32812: Crankshaft installer

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Install the reverse dog and washer 1.

Install the reverse driven gear and washer 2.

Reassemble the shift cam lock shaft.

Install the shift cam lock shaft by fitting the spring end to the
stopper properly.

ENGINE

Install the gearshift cam.
Install the gearshift forks and shafts as shown.
NOTE:
Each fork differs in shape.

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1 For reverse/1st gear
2 For 2nd/3rd gear
3 For 4th/5th gear

Install the reverse idle gear shaft 4.
Install the snap ring 5, washer 6 and spacer 7.

Install the reverse idle gear 8 and washer 9.

OIL SUMP FILTER
Clean the oil sump filter by using compressed air.

3-61

3-62

ENGINE

Install the oil sump filter as its projection A faces upward.

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CRANKCASE
Wipe the crankcase mating surfaces (both surfaces) with a
cleaning solvent.
Fit the dowel pins onto the left half on the crankcase.
Apply engine oil to the conrod big end and gears.

Apply SUZUKI BOND to the mating surface of the right crankcase.

, 99104-31140: SUZUKI BOND 1207B (USA)
- 99000-31110: SUZUKI BOND 1215 (Others)

ENGINE

Assemble the crankcase within a few minutes.
NOTE:
Fit the clamp to the bolt A.

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" Crankcase bolt: 11 N•m (1.1 kgf-m, 8.0 lb-ft)

CAM CHAIN
Install the cam chain.

GENERATOR
Install the starter driven gear 1.
Install the key 2.

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

Install the generator rotor and tighten the generator rotor nut
to the specified torque with the special tool.
" Generator rotor nut: 160 N•m (16.0 kgf-m, 115.5 lb-ft)
& 09930-44520: Rotor holder

3-63

3-64

ENGINE

OIL PUMP
Install the oil pump.
Install the washer 1 and pin 2.

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Install the oil pump driven gear and E-ring.

OIL PUMP DRIVE GEAR
Install the pin 1.
Install the oil pump drive gear.

NOTE:
Flange side of the gear is positioned inside.

GEARSHIFT
Install the spring 1, washer 2 and gearshift cam stopper 3.
NOTE:
Fit the spring end to the stopper properly.

Install the the gearshift cam plate 4.

ENGINE

3-65

Apply THREAD LOCK to the gearshift cam bolt and install the
gearshift cam plate guide.
$ 99000-32050: THREAD LOCK 1342

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Install the gearshift cam shaft assembly so that the stopper 5
comes between the spring ends 6.

Install the washer 7 and gearshift arm.

CLUTCH
Apply engine oil to each of the clutch drive/driven plate.
Install the clutch drive/driven plates one by one onto the
clutch sleeve hub 1.
DRIVE PLATE (Black)....... 5 pcs
(Gray)........ 1 pc
DRIVEN PLATE ................. 5 pcs

NOTE:
The gray drive plate should be installed at the last.

Black (Cork)

Gray (Paper)

3-66

ENGINE

Install the clutch pressure plate 2.
Align the clutch drive plates in line to facilitate later assembly.

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Install the washer 3 onto the countershaft.

Install the primary driven gear assembly.
Install the washer 4.

Install the clutch sleeve hub assembly into the primary driven
gear assembly.

Install the washer and clutch sleeve hub nut.
NOTE:
The convex side of the washer faces outside.
INSIDE
OUTSIDE

Washer

ENGINE

Tighten the clutch sleeve hub nut to the specified torque with
the special tool.
" Clutch sleeve hub nut: 100 N•m (10.0 kgf-m, 72.5 lb-ft)
& 09920-53730: Clutch sleeve hub holder

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Stake the clutch sleeve hub nut with a center punch.

Install the clutch springs and clutch release plate.
Tighten the clutch spring bolts diagonally.

Install the one-way clutch onto the clutch wheel with the ➞
mark facing inside.
Install the one-way clutch inner race with the groove A facing
inside.

Install the clutch wheel assembly.

3-67

3-68

ENGINE

Install the clutch shoes.
Install the washer as its convex side faces outside.
Before installing the clutch shoe nut, apply engine oil to the
thread and inside surface of the nut.

INSIDE
OUTSIDE

Washer

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While holding the generator rotor with the special tool, tighten
the clutch shoe nut to the specified torque.
& 09930-44520: Generator rotor holder
'

The clutch shoe nut has left-hand threads.

" Clutch shoe nut: 140 N•m (14.0 kgf-m, 101.5 lb-ft)

Install the clutch release arm 1 and washer 2 clutch release
ball inner guide 3 and release ball assembly 4.

CLUTCH COVER
Install the dowel pins and new gasket.

Install the clutch cover.

ENGINE

OIL FILTER
Before installing the oil filter, fit new O-rings and apply engine
oil lightly to them.
Install the spring 1 and oil filter 2.
'
Use new O-rings to prevent oil leakage.

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STARTER IDLE GEAR
Install the idle driven gear 1, shaft 2 and spacer 3.

GENERATOR COVER
Install the dowel pins and new gasket.

Install the reverse lock release cable holder 4 and tighten the
generator cover bolt.

SECONDARY DRIVEN BEVEL GEAR
Install the secondary driven bevel gear shaft assembly 1.
Install the dowel pins.

3-69

3-70

ENGINE

Apply SUZUKI BOND to the mating surface of the secondary
bevel gear cover.
, 99104-31140: SUZUKI BOND 1207B (USA)
- 99000-31110: SUZUKI BOND 1215 (Others)

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Install the secondary bevel gear cover.

NEUTRAL SWITCH
Install the springs and switch contacts.
Fit new O-ring and install the neutral switch 1.
Tighten the neutral switch bolts to the specified torque.

" Neutral switch bolt: 7 N•m (0.7 kgf-m, 5.0 lb-ft)

ENGINE TOP SIDE

PISTON
Install the piston rings in the order of oil ring, 2nd ring and 1st
ring.
The first member to go into the oil ring groove is a spacer 1.
After placing the spacer, fit the two side rails 2.
NOTE:
Side designations, top and bottom, are not applied to the spacer
and side rails: Those can be positioned each either way.
'

INCORRECT

When installing the spacer, be careful not to allow its
two ends to overlap in the groove.

CORRECT

ENGINE

3-71

Install the 2nd ring 3 and the 1st ring 4.
NOTE:
1st ring and 2nd ring differ in shape.

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1st ring has letter R marked on the side. Be sure to bring the
marked side to the top when fitting it to the piston.

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

2nd ring
Lower side
rail

Apply engine oil to the piston pin.
Install the piston and piston pin.

NOTE:
When installing the piston, the punched mark A on the piston
head is located to the exhaust side.

Place a cloth beneath the piston, install the circlip 5.
'
Use new piston pin circlips to prevent circlip failure
with bent ones.

1st ring

Upper side
rail

1st ring
Spacer

3-72

ENGINE

CYLINDER
Fit the dowel pins and new gasket 1.
'
Use a new gasket to prevent gas leakage.

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NOTE:
* The dowel pins are identified by their length.
* Shorter ones A are for cylinder base.
* Apply engine oil to the piston ring grooves and cylinder wall.

Hold each piston ring with proper position, insert the piston
into the cylinder.
!

When installing the cylinder and cylinder head, pull
the cam chain upward, or the chain will be caught
between the crankcase and cam drive sprocket.

Tighten the cylinder base nuts (M6) temporarily.

NOTE:
Fit the clamp under the nut B.

CYLINDER HEAD
Install the cam chain guide 1.
Fit the dowel pins and new cylinder head gasket 2.
'
Use new gasket to prevent gas leakage.

ENGINE

Install the cylinder head.
Install the washers and cylinder head nuts (M8) as shown.

IN.

EX.

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Tighten the cylinder head nuts (M8) diagonally to the specified torque.
" Cylinder head nut (M8): 23 N•m (2.3 kgf-m, 16.5 lb-ft)

Tighten the cylinder base nuts (M6) 3 and head nuts (M6) 4
to the specified torque.

" Cylinder base nut (M6): 10 N•m (1.0 kgf-m, 7.0 lb-ft)
Cylinder head nut (M6): 10 N•m (1.0 kgf-m, 7.0 lb-ft)

CAMSHAFT
Turn the crankshaft until the TDC line A on the generator
rotor aligns with the index mark B on the crankcase.
'

Pull the cam chain upward, or the chain will be caught
between crankcase and cam drive sprocket.

NOTE:
Before installing the camshaft to the cylinder head, apply engine
oil to the camshaft journals and cam faces.

3-73

3-74

ENGINE

Install the camshaft and camshaft sprocket.
Engage the hole of the sprocket C with the locating pin on the
camshaft as shown.
Align the lines D on the camshaft so that they are parallel
with the surface of the cylinder head.

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NOTE:
* Do not rotate the generator while doing this. When the
sprocket is not positioned correctly, turn the sprocket.
* While aligning the lines D, remove chain slack by turning the
sprocket counterclockwise lightly.
Install the C-ring 1.

Install the lock washer as it covers the locating pin.
Apply THREAD LOCK SUPER to the bolts and tighten them
to the specified torque.
* 99000-32030: THREAD LOCK SUPER 1303

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

Bend up the washer tongue to lock the bolts.
2 Camshaft
3 Pin
4 Bolt
5 Lock washer
6 Camshaft sprocket

ENGINE

3-75

Turn the crankshaft until the TDC line E on the generator
rotor aligns with the index mark F on the crankcase.

CYLINDER HEAD COVER
Clean the mating surface of the cylinder head and head cover
before matching.
Install the dowel pins to the cylinder head.
Apply SUZUKI BOND to the periphery of the camshaft end
cap 1 and fit it

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1216

99000-31230: SUZUKI BOND 1216B

Apply SUZUKI BOND to the mating surface of the cylinder
head cover.
1216

99000-31230: SUZUKI BOND 1216B

1216

Tighten the cylinder head cover bolts to the specified torque.

" Cylinder head cover bolt: 10 N•m (1.0 kgf-m, 7.0 lb-ft)
'

Fit the washer to the bolt A.

CAM CHAIN TENSION ADJUSTER
After removing the spring holder bolt and spring, unlock the
ratchet mechanism 1 and push in the push rod 2 all the way.
NOTE:
Before installing the cam chain tension adjuster, unlock the
ratchet mechanism 1 and move the push rod 2 in place to see
if it slides smoothly.

3-76

ENGINE

Install new gasket 3 and cam chain tension adjuster to the
cylinder block and tighten its mounting bolts to the specified
torque.
" Cam chain tension adjuster bolt:
10 N•m (1.0 kgf-m, 7.0 lb-ft)
Install new O-ring 4.

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Install the spring and pin 5.
Tighten the spring holder bolt 6 to the specified torque.

" Cam chain tension adjuster spring holder bolt:
8 N•m (0.8 kgf-m, 6.0 lb-ft)
Adjust the valve clearance. (!2-5)

Tighten the valve timing inspection plug 7 and generator
cover cap 8 to the specified torque.

" Valve timing inspection plug:
23 N•m (2.3 kgf-m, 16.5 lb-ft)
Generator cover cap: 15 N•m (1.5 kgf-m, 11.0 lb-ft)

STARTER MOTOR
Apply SUZUKI SUPER GREASE to new O-ring.

# 99000-25030: SUZUKI SUPER GREASE A (USA)
99000-25010: SUZUKI SUPER GREASE A (Others)

Install the starter motor and tighten the starter mortor mounting bolts to the specified torque.
" Starter motor mounting bolt: 10 N•m (1.0 kgf-m, 7.0 lb-ft)

SPARK PLUG
Tighten the spark plug to the specified torque. (!2-8)
" Spark plug: 18 N•m (1.8 kgf-m, 13.0 lb-ft)
& 09930-10121: Spark plug wrench set
Mount the engine. (!3-8)

DRIVE TRAIN

4-1

DRIVE TRAIN

CONTENTS

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REAR DRIVING SYSTEM ...............................................................................4- 2
REAR DRIVE REMOVAL .......................................................................4- 3
REAR DRIVE DISASSEMBLY ...............................................................4- 4
REAR DRIVE INSPECTION ...................................................................4- 9
REAR DRIVE REASSEMBLY ................................................................4-11
REAR DRIVE INSTALLATION ..............................................................4-16
SHIM ADJUSTMENT .............................................................................4-18
REASSEMBLY INFORMATION .............................................................4-21

4-2

DRIVE TRAIN

REAR DRIVING SYSTEM

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1 Final gear case cover
2 Shim, LH
3 Bevel ring gear
4 Shim, RH
5 Final gear case
6 Shim
7 Bevel pinion gear
8 Pinion gear shaft coupling joint
9 Propeller shaft
0 Universal joint

DRIVE TRAIN

REAR DRIVE REMOVAL
Remove the final gear case under cover 1.
Drain gear oil. (!2-11)

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Remove the rear wheels. (!7-11)
Remove the rear wheel hubs. (!7-11)
Remove the rear brake 2. (!7-46)

Remove the axle housing set bolts/nuts.
Remove the final gear case together with the propeller shaft.

Remove the propeller shaft and spring 3 from the final gear
case.

Remove the axle housing/final gear case bolts.

4-3

4-4

DRIVE TRAIN

Remove the rear axle together with the axle housing.
Remove the O-ring 4.

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REAR DRIVE DISASSEMBLY
FINAL GEAR CASE
Remove the final gear case cover bolts diagonally and evenly.
Pry the cover at the arrows as shown by tapping with a plastic
mallet.

Remove the ring gear and shims.

Remove the dust seal with the special tool.

" 09913-50121: Oil seal remover

NOTE:
If there is no abnormal condition, the dust seal removal is not
necessary.
#

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

DRIVE TRAIN

Remove the snap ring.

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Remove the O-ring 1.
Drive out the bearing from the other side with the special tool.
" 09913-70210: Bearing installer set

NOTE:
If there is no abnormal condition, the bearing removal is not necessary.
#

The removed bearing must be replaced with a new
one.
Remove the bearing and oil seal with a suitable tool.

NOTE:
If there is no abnormal condition, the bearing/oil seal removal is
not necessary.
#

The removed bearing and oil seal must be replaced
with the new ones.

Remove the oil seal with a suitable tool.

NOTE:
If there is no abnormal condition, the oil seal removal is not necessary.
#

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

4-5

4-6

DRIVE TRAIN

Remove the bearing with the special tool.
" 09913-70210: Bearing installer set
NOTE:
If there is no abnormal condition, the bearing removal is not necessary.
#
The removed bearing must be replaced with a new
one.

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Remove the pinion gear shaft coupling joint with the special
tools.
" 09923-74510: Bearing remover
09930-30104: Sliding shaft

Remove the oil seal with a suitable tool.

NOTE:
If there is no abnormal condition, the oil seal removal is not necessary.
#

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

Unstake the bearing locknut with a small chisel or drill.

Remove the bearing locknut with the special tool.
" 09921-21820: Bearing locknut wrench
#
Replace the bearing locknut with a new one.

DRIVE TRAIN

Remove the pinion gear assembly and shim.

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Remove the stopper ring 1 and O-ring 2.

Remove the bearing with a commercially available bearing
puller or a hydraulic press.
NOTE:
If there is no abnormal condition, the bearing removal is not necessary.
#

The removed O-ring and bearing must be replaced
with the new ones.

Remove the pinion gear pilot bearing with the special tools.

" 09921-20210: Bearing remover
09930-30104: Sliding shaft

NOTE:
If there is no abnormal condition, the bearing removal is not necessary.
#
The removed bearing must be replaced with a new
one.

4-7

4-8

DRIVE TRAIN

UNIVERSAL JOINT
Remove the C-rings from the universal joint.
#
Replace the removed C-rings with new ones.

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Remove the bearings by tapping with the special tool and a
hammer.
" 09913-70210: Bearing installer set

Remove the universal joint.

DRIVE TRAIN

REAR DRIVE INSPECTION
PROPELLER SHAFT
Inspect the splines of the propeller shaft for wear or damage.
Also, inspect the boot for cuts or damage.
If any defects are found, replace the propeller shaft and its boot
with new ones.

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UNIVERSAL JOINT
Inspect the universal joint and outer surface of the bearing for
scuffing, wear and damage. If any defects are found, replace the
bearings and universal joint as a set.

Insert the universal joint to the bearing and check the play by
turning the universal joint, as shown. If excessive play is noted,
replace the bearing with a new one.

FINAL GEAR CASE
Inspect the gear case, case cover, oil seals and dust seal for
wear or damage.
If any wear or damage is found, replace the oil seal or dust seal
with a new one.
OIL SEAL REMOVAL !4-4 to -6

4-9

4-10

DRIVE TRAIN

Check the outer race play and smooth rotation of the bearing by
hand while it is on the pinion gear shaft.
Inspect the pinion gear for wear or damage.
If the pinion gear is damaged, inspect the ring gear also.
If any defects are found, replace the bearing and gear with the
new ones.
BEARING AND GEAR REMOVAL !4-7

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Inspect the ring gear for wear or damage.
If the ring gear is damaged, inspect the pinion gear.
If any defects are found, replace the ring gear with a new one.

Check the gear case and case cover bearings for wear or damage.
If any wear or damage is found, replace the bearing with a new
one.

BEARING REMOVAL !4-5 to -7

Check the breather rubber case for wear or damage. Also,
check that the joint of the rubber case fits tightly.

DRIVE TRAIN

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REAR AXLE
Inspect the splines of the rear axle and splines of the ring gear
for wear or damage.
If any wear or damage is found, replace the rear axle and ring
gear with the new ones.
Check the axle shaft runout. (!7-61)

REAR DRIVE REASSEMBLY

Reassemble the rear drive in the reverse order of disassembly.
Pay attention to the following points:
NOTE:
Before reassembly, thoroughly clean all parts in cleaning solvent.

FINAL GEAR CASE OIL SEAL
Install new oil seals into the gear case and case cover with
the special tool.
Apply SUZUKI SUPER GREASE to the new oil seal lips.

" 09913-70210: Bearing installer set

$ 99000-25030: SUZUKI SUPER GREASE A ( USA)
99000-25010: SUZUKI SUPER GREASE A ( Others)

NOTE:
The marked side of the oil seal should be positioned outside.
(!4-21)

4-11

4-12

DRIVE TRAIN

FINAL GEAR CASE BEARING
Drive the bearings into the gear case and case cover with the
special tool.

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" 09913-70210: Bearing installer set

DUST SEAL
Fix the bearing race with the snap ring.
Apply SUZUKI SUPER GREASE to the bearing.

$ 99000-25030: SUZUKI SUPER GREASE A ( USA)
99000-25010: SUZUKI SUPER GREASE A (Others)

Install new dust seal with the special tool and then apply
SUZUKI SUPER GREASE to the seal lip.
" 09913-70210: Bearing installer set
$ 99000-25030: SUZUKI SUPER GREASE A ( USA)
99000-25010: SUZUKI SUPER GREASE A (Others)

DRIVE TRAIN

BEVEL PINION GEAR SHAFT BEARING
Drive the bearing onto the shaft with the special tool.
" 09913-70210: Bearing installer set

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BEVEL PINION GEAR/SHIM/LOCKNUT
[FINAL ASSEMBLY]
Install new O-ring 1 onto the pinion gear shaft.
Install the shim, pinion gear assembly and new bearing
locknut.
Tighten new bearing locknut to the specified torque.
" 09921-21820: Bearing locknut wrench

% Bearing locknut: 100 N•m (10.0 kgf-m, 72.5 lb-ft)

NOTE:
After the backlash and tooth contact have been checked or
adjusted (!4-18), stake the nut with a center punch.

4-13

4-14

DRIVE TRAIN

BEVEL PINION GEAR SHAFT OIL SEAL
Install new stopper ring to pinion gear shaft securely.

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Install new oil seal to the gear case with the special tool.
Apply SUZUKI SUPER GREASE to the new oil seal lip
groove.
" 09913-85210: Bearing/oil seal installer

$ 99000-25030: SUZUKI SUPER GREASE A ( USA)
99000-25010: SUZUKI SUPER GREASE A (Others)
NOTE:
After the backlash and tooth contact have been checked or
adjusted, install the oil seal.

Apply SUZUKI SUPER GREASE to the splines of the pinion
gear shaft and install the pinion gear shaft coupling joint by
tapping with a plastic mallet.
$ 99000-25030: SUZUKI SUPER GREASE A ( USA)
99000-25010: SUZUKI SUPER GREASE A (Others)

Apply 4 5 gram of WATER RESISTANCE GREASE to the
outside of seal lip groove.

& 99000-25160: WATER RESISTANCE GREASE

BEVEL RING GEAR/SHIM
Fit the removed shims 1 on both sides of the ring gear, then
install the ring gear 2.

DRIVE TRAIN

FINAL GEAR CASE COVER/GEAR CASE
[FINAL ASSEMBLY]
Coat new O-ring with SUZUKI SUPER GREASE and apply
SUZUKI BOND to the mating surface of the cover, then install
the gear case cover.
$ 99000-25030: SUZUKI SUPER GREASE A ( USA)
99000-25010: SUZUKI SUPER GREASE A ( Others)
' 99104-31140: SUZUKI BOND 1207B (USA)
( 99000-31110: SUZUKI BOND 1215 (Others)

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NOTE:
After the backlash and tooth contact have been checked or
adjusted (!4-18), install new O-ring and apply SUZUKI
BOND.
Apply THREAD LOCK SUPER to the case cover bolts and
tighten them to the specified torque in a crisscross pattern.
) 99000-32030: THREAD LOCK SUPER 1303

% Gear case cover bolt: 26 N•m (2.6 kgf-m, 19.0 lb-ft)

NOTE:
After the backlash and tooth contact have been checked or
adjusted, apply THREAD LOCK SUPER to the case cover bolts.

UNIVERSAL JOINT
Apply SUZUKI SUPER GREASE to the bearing and its dust
seal lip.

$ 99000-25030: SUZUKI SUPER GREASE A ( USA)
99000-25010: SUZUKI SUPER GREASE A ( Others)

Install the universal joint and bearings with the special tool.
" 09913-70210: Bearing installer set

4-15

4-16

DRIVE TRAIN

Install new C-rings by tapping with a copper hammer.

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After reassembling the universal joint, check the joint movement smoothly. If a large resistance is felt to movement, tap
the bearing with a plastic mallet lightly.

REAR DRIVE INSTALLATION

Install the rear drive in the reverse order of removal. Pay attention to the following points:

Coat new O-ring with SUZUKI SUPER GREASE and install it
into the groove in the gear case.

$ 99000-25030: SUZUKI SUPER GREASE A ( USA)
99000-25010: SUZUKI SUPER GREASE A (Others)

Apply SUZUKI SUPER GREASE to the splines of the axle.

$ 99000-25030: SUZUKI SUPER GREASE A ( USA)
99000-25010: SUZUKI SUPER GREASE A (Others)

Apply THREAD LOCK SUPER to the axle housing/final gear
case bolts, and tighten them to the specified torque.
) 99000-32030: THREAD LOCK SUPER 1303
% Axle housing/final gear case bolt:
65 N•m (6.5 kgf-m, 47.0 lb-ft)

DRIVE TRAIN

Install the spring into the rear end of the propeller shaft.
Apply SUZUKI SUPER GREASE to the splines of the propeller shaft.

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$ 99000-25030: SUZUKI SUPER GREASE A ( USA)
99000-25010: SUZUKI SUPER GREASE A ( Others)

Tighten the axle housing set bolts/nuts 1 (RH) and 2 (LH) to
the specified torque of each.

% Axle housing set bolt/nut 1 (RH):
60 N•m (6.0 kgf-m, 43.5 lb-ft)
Axle housing set bolt/nut 2 (LH):
65 N•m (6.5 kgf-m, 47.0 lb-ft)

Pour the specified hypoid gear oil (SAE #90) in through the
filler hole. (!2-12)
Install the rear brake. (!7-51)
Install the rear wheels. (!7-15)

4-17

4-18

DRIVE TRAIN

SHIM ADJUSTMENT
BACKLASH
Install the pinion gear assembly, removed shim and new
bearing locknut. (!4-13)
Tighten the bearing locknut to the specified torque.
(!4-13)
NOTE:
At this time, it is not necessary to stake the bearing locknut.
(!4-13)

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Install the removed right side shim and ring gear. (!4-14)
Measure the backlash using the dial gauge, as shown. Take
backlash readings at several places while turning the pinion
gear shaft in each direction and securely holding the ring
gear. If the backlash is not within specification, the shim must
be changed and the backlash should be re-checked until correct. Refer to the chart at the right for the appropriate shim
thickness.
* Backlash
Standard: 0.05

0.30 mm (0.0020 0.0 118 in)

NOTE:
Adjust the backlash by referring to the chart at the right and
using the thickness of the removed shim as a guide.

Part No.

4-21)

Shim thickness

1.26 mm (0.0496 in)
1.32 mm (0.0520 in)

Shim adjustment

1.38 mm (0.0543 in)

Increase shim thickness

27407-05820

(Shim set: 10 pcs)

Correct

Backlash
Under 0.05 mm
(0.0020 in)
0.05 0.30 mm
(0.0020 0 .0118 in)
Over 0.30 mm
(0.0118 in)

For right side of ring gear (

Decrease shim thickness

LEFT SIDE SHIM SELECTION
After the backlash has been checked or adjusted, put a few
pieces of solder A (O.D.: 1.4 2 .0 mm L: 6 mm) on the ring
gear back side, as shown.

NOTE:
* Do not install the left side shim at this time.
* Apply a small quantity of grease to the solders to prevent them
from falling.

1.44 mm (0.0567 in)
1.50 mm (0.0591 in)
1.56 mm (0.0614 in)
1.62 mm (0.0638 in)
1.68 mm (0.0661 in)
1.74 mm (0.0685 in)
1.80 mm (0.0709 in)

DRIVE TRAIN

4-19

Install the final gear case cover and tighten its bolts to the
specified torque in a crisscross pattern. (!4-15)
NOTE:
* It is not necessary to install the O-ring to the final gear case
cover at this time.
* Do not apply THREAD LOCK SUPER to the final gase cover
bolts at this time.
% Final gear case cover bolt: 26 N•m (2.6 kgf-m, 19.0 lb-ft)

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Remove the final gear case cover. (!4-4)
Measure the thickness of compressed solder with the
micrometer.
" 09900-20205: Micrometer

Select the proper size of shim from the right chart, according
as the compressed solder thickness.
After selecting the proper size of shim, install it on the ring
gear back side.

For left side of ring gear (
Part No.

4-21)

Shim thickness

1.26 mm (0.0496 in)
1.32 mm (0.0520 in)
1.38 mm (0.0543 in)

27407-05820

(Shim set: 10 pcs)

1.44 mm (0.0567 in)
1.50 mm (0.0591 in)

1.56 mm (0.0614 in)
1.62 mm (0.0638 in)
1.68 mm (0.0661 in)
1.74 mm (0.0685 in)
1.80 mm (0.0709 in)

4-20

DRIVE TRAIN

Incorrect

(Contact at tooth top)

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TOOTH CONTACT
After backlash adjustment and left shim selection are carried
out, the tooth contact must be checked. Pay attention to the following procedures:
Remove the ring gear.
Clean and degrease several teeth on the ring gear and pinion
gear, and then apply a coating of machinist s layout dye or
paste to several teeth of the pinion gear.
Install the ring gear with the shims in place.
Install the final gear case cover, and then tighten the bolts to
the specified torque in a crisscross pattern. (!4-15)
% Final gear case cover bolt: 26 N•m (2.6 kgf-m, 19.0 lb-ft)

NOTE:
At this time, it is not necessary to install the gear case cover s Oring.

Rotate the gear several turns in each direction. This will provide a contact pattern on the coated teeth of the gear.
Remove the ring gear and compare the coated teeth to the
examples shown in 1, 2 and 3.
If tooth contact is found to be correct (example 2), go to
the FINAL ASSEMBLY sub-section on page 4-13 to -15 to
complete installation.
If tooth contact is found to be incorrect (examples 1 and 3),
the shim between the pinion gear bearing and gear case must
be changed and the tooth contact re-checked until correct.

Shim adjustment
Decrease shim thickness
Increase shim thickness

Tooth contact
Contact at tooth top 1
Contact at tooth root 3

Make sure to check the backlash and shim thickness
after the tooth contact has been adjusted, since it may
have changed. Adjust the tooth contact and backlash
until they are both within specification. If the correct
tooth contact cannot be maintained when adjusting
the backlash, replace the pinion gear and ring gear as
a set.

Correct

Incorrect

(Contact at tooth root)

For pinion gear (
Part No.

4-21)

Shim thickness

1.38 mm (0.0543 in)
1.44 mm (0.0567 in)

27407-05810

1.50 mm (0.0591 in)

(Shim set: 6 pcs)

1.56 mm (0.0614 in)
1.62 mm (0.0638 in)
1.68 mm (0.0661 in)

DRIVE TRAIN

4-21

REASSEMBLY INFORMATION

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4 5 g ram

100 N.m
(10.0 kgf-m, 72.5 lb-ft)

Pinion gear shim

Left side of
ring gear shim
Right side of
ring gear shim
26 N•m
(2.6 kgf-m, 19.0 lb-ft)

26 N•m
(2.6 kgf-m, 19.0 lb-ft)
Matching surfaces

4 5 g ram

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4-22
DRIVE TRAIN

FUEL SYSTEM

5-1

FUEL SYSTEM

CONTENTS

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FUEL TANK ...................................................................................................5- 2
CONSTRUCTION ....................................................................................5- 2
FUEL LINE INSPECTION .......................................................................5- 3
REMOVAL ...............................................................................................5- 3
REMOUNTING ........................................................................................5- 3
FUEL VALVE .................................................................................................5- 4
REMOVAL AND INSPECTION ...............................................................5- 4
FUEL STRAINER ....................................................................................5- 4
REMOUNTING ........................................................................................5- 4
CARBURETOR ..............................................................................................5- 5
CONSTRUCTION ....................................................................................5- 5
SPECIFICATIONS...................................................................................5- 6
I.D. NO. LOCATION ................................................................................5- 6
REMOVAL ...............................................................................................5- 7
DISASSEMBLY .......................................................................................5- 8
CLEANING ..............................................................................................5-12
INSPECTION ...........................................................................................5-12
REASSEMBLY ........................................................................................5-13
REMOUNTING ........................................................................................5-15

5-2

FUEL SYSTEM

FUEL TANK
CONSTRUCTION

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1 Fuel tank
2 Fuel cap
3 Breather hose
4 Gasket
5 Seal washer
6 Fuel valve
7 Fuel hose

FUEL SYSTEM

FUEL LINE INSPECTION
Inspect the fuel lines, fuel tank, fuel tank breather hoses and fuel
tank cap for damage, clogging and leakage of fuel. If any damages are found, replace the defective parts with the new ones.

REMOVAL
Remove the front fender. (!7-6)
Turn the fuel valve to the ON position.
Disconnect the fuel hose 1 and vacuum hose 2.

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"
Gasoline is highly flammable and explosive. Keep
heat, sparks and flames away from gasoline.

Remove the air cIeaner duct 3.
Remove the fuel tank 4.
Drain fuel completeIy.

REMOUNTING

Remount the fuel tank in the reverse order of removal.

5-3

5-4

FUEL SYSTEM

FUEL VALVE
REMOVAL AND INSPECTION
Remove the fuel tank. (!5-3)
Drain fuel completely.
Remove the fuel valve.
"

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Gasoline is highly flammable and explosive. Keep
heat, sparks and flames away from gasoline.

FUEL STRAINER

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

REMOUNTING

Remount the fuel valve in the reverse order of removal.
"

Replace the removed gasket 1 and seal washers 2
with the new ones to prevent leakage of fuel.

FUEL SYSTEM

CARBURETOR
CONSTRUCTION

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1 Top cap
2 Spring
3 Holder
4 O-ring
5 Spring
6 Washer (t=0.5 mm, 0.02 in)
7 E-ring
8 Spacer
9 Washer (t=1.0 mm, 0.04 in)
0 Jet needle
A Diaphragm
B Ring
C Piston valve
D Vacuum hose
E Air vent hose
F Side cover
G O-ring
H Coasting enrichment valve
I Coasting enrichment valve cover
J Starter plunger
K Pilot air jet
L Pilot jet
M Needle valve
N Needle jet
O O-ring
P Starter jet
Q Needle jet holder
R Main jet ring
S Main jet
T Float
U O-ring
V Washer
W Spring
X Pilot screw
Y Throttle stop screw
Z O-ring
[ Float chamber

5-5

5-6

FUEL SYSTEM

SPECIFICATIONS
SPECIFICATION

ITEM

E-19, 28
MIKUNI BSR29
29.0 mm
(1.14 in)
21G0
1 500 – 100 r/min
13.0 – 1.0 mm
(0.51 – 0.04 in)

Carburetor type
Bore size
I.D. No.
Idle r/min
Float height

Jet needle
Needle jet
Pilot jet
Pilot screw
Throttle cable play

21G1
←
←

(M.J.)

#125

(J.N.)

5DH54-2nd

(N.J.)

P-0M

(P.J.)

#20

(P.S.)

1-1/2 turns back

PRE-SET

3 5 mm
(0.12 0.20 in)
0.5 1 .0 mm
(0.02 0.04 in)

←

Starter (enricher) plunger cable play
E-19: EU

←

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Main jet

E-33
←

E-28: Canada

E-33: USA (California)

I.D. NO. LOCATION

Carburetor has an I.D. number 1 printed on its body.

←

FUEL SYSTEM

REMOVAL
Remove the seat. (!7-5)
Disconnect the air vent hose 1.

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Disconnect the fuel hose 2 and vacuum hose 3.

Disconnect the starter cable 4.
Loosen the carburetor clamp screws.
Pull out the carburetor from between the engine and air
cleaner.

Remove the carburetor side cover 5.

Remove the O-ring 6.
Disconnect the throttle cable 7.
Remove the carburetor.

5-7

5-8

FUEL SYSTEM

DISASSEMBLY
Remove the fuel hose 1, overflow hose 2, vacuum hose 3
and air vent hose 4.

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Remove the throttle stop screw 5.

Remove the carburetor top cap.
#

Do not use compressed air on the carburetor body
before removing the diaphragm; this may damage the
diaphragm.

Remove the spring and diaphragm assembly 6.

Remove the jet needle holder.

FUEL SYSTEM

7
8
9
0
A
B

Remove the following parts.
Jet needle holder
O-ring
Spring
Washer (t=0.5 mm, 0.02 in)
Jet needle
Washer (t=1.0 mm, 0.04 in)

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Remove the diaphragm by removing the ring C.

Remove the coasting enrichment valve cover D and spring.

Remove the coasting enrichment valve E.

Remove the pilot air jet F.

5-9

5-10

FUEL SYSTEM

Remove the float chamber.

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Remove the O-ring G.

Replace the removed O-ring with a new one to prevent
leakage of fuel.

Remove the float pin H, float I and needle valve J.

Remove the valve seat K.

FUEL SYSTEM

L
M
N
O

Remove the following parts.
Main jet, main jet ring, needle jet holder and needle jet
Pilot screw
Starter jet
Pilot jet

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NOTE:
Before removing the pilot screw M, its setting must be determined. Slowly turn the pilot screw clockwise and count the number of turns until it is lightly seated. Make a note of how many
turns were made.
When reassembling the pilot screw, you will want to set it to its
original position.

Do not use wire to clean the passageways, valve seat
and jets. Use compressed air only.

PILOT SCREW REMOVAL (FOR E-33)
Because harsh cleaning solvents can damage the O-ring seals
in the pilot system, the pilot system components should be
removed before cleaning.

Use a 1/8" size drill bit with a drill-stop to remove the pilot
screw plug. Set the drill-stop 4 mm (0.16 in) from the end of
the bit to prevent drilling into the pilot screw. Carefully drill
through the plug.
Thread a self-tapping sheet metal screw into the plug. Pull on
the screw head with pliers to remove the plug. Carefully clean
any metal shavings from the area.
Slowly turn the pilot screw clockwise and count the number of
turns until the screw is lightly seated. Make a note of how
many turns were made so the screw can be reset correctly
after cleaning.
Remove the pilot screw along with the spring, washer and Oring.
After cleaning, install the pilot screw to the original setting by
turning the screw in until it lightly seats, and then backing it
out the same number of turns counted during disassembly.
Install a new plug by tapping it into place with a punch.

1
2
3
4

Drill-stop
Plug
Pilot screw
Carburetor body

5-11

5-12

FUEL SYSTEM

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

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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 a wire to clean the jets or passageways. If
wire is used, the jets and passageways may become
damaged. If the components cannot be cleaned with a
spray-type cleaner it may be necessary to soak the
components 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.

Replace the removed O-rings with new ones.

INSPECTION

Check the following items for any damage or clogging. If any
damages are found, replace the damaged parts with new ones.
* Pilot jet
* Piston valve
* Main jet
* Starter jet
* Pilot screw
* O-rings
* Pilot air jet
* Throttle valve
* Needle jet holder
* Diaphragms
* Float
* Pilot outlet and by-pass ports
* Needle valve
* Vacuum hose
* Valve seat
* Air vent hose
* Jet needle
* Overflow hose
* Needle jet
* Fuel hose

FUEL SYSTEM

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NEEDLE VALVE INSPECTION
If foreign matter is caught between the valve seat and the needle valve, the gasoline will continue flowing and overflow. If the
valve seat and needle valve are worn beyond the permissible
limits, similar trouble will occur. Conversely, if the needle valve
sticks, the gasoline will not flow into the float chamber. Clean the
float chamber and float parts with gasoline. If the needle valve is
worn as shown, replace and the valve seat with a new one.
Clean the fuel passage of the mixing chamber using compressed air.
FLOAT HEIGHT ADJUSTMENT
To check the float height, turn the carburetor upside down.
Measure the float height A while the float arm is just contacting
the needle valve using vernier calipers.
Bend the tongue as necessary to bring the float height A to the
specified level.
$ Float height A: 13.0 – 1.0 mm (0.51 – 0.04 in)
% 09900-20101: Venier calipers

REASSEMBLY

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

PILOT SCREW
After cleaning, install the pilot screw 1 to the original setting
by turning the screw in until it lightly seats, and then backing it
out the same number of turns counted during disassembly.
1 Pilot screw
2 Carburetor body
#

Replace the removed O-ring with a new one.

NEEDLE JET
Install the needle jet with its smaller internal diameter portion
facing to the needle jet holder.

5-13

5-14

FUEL SYSTEM

VALVE SEAT
Install the valve seat 1 into the carburetor body, and then
tighten the screw 2.
NOTE:
Make sure that the collar of the screw 2 holds the step of the
valve seat 1 securely.

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DIAPHRAGM
Install the diaphragm to the piston valve with the lug on the
diaphragm aligned with the cutout on the piston valve.
Install the ring 1 to the piston valve.

Install the diaphragm assembly.

NOTE:
When installing the diaphragm, make sure the tab of the diaphragm is aligned with the concave section of the carburetor
body s rim.

THROTTLE STOP SCREW
Apply SUZUKI SUPER GREASE to thread part of the throttle
stop screw, then install the throttle stop screw to the carburetor.
& 99000-25030: SUZUKI SUPER GREASE A ( USA)
99000-25010: SUZUKI SUPER GREASE A (Others)

FUEL SYSTEM

REMOUNTING
Remount the carburetor assembly in the reverse order of
removal. Pay attention to the following points:
Fit the lug on the carburetor with the intake pipe s projection.

Left

Right

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Position the carburetor clamps as shown in the illustration.
Connect the carburetor hoses properly. (!9-16)

Engine side

After the carburetor assembly has been remounted onto the
engine, perform the following adjustments:

* Throttle cable play......................................... !2-9
* Engine idle speed ......................................... !2-9

Left

Right

45ß

Air cleaner side

5-15

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LUBRICATION SYSTEM

6-1

LUBRICATION SYSTEM

CONTENTS

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LUBRICATION SYSTEM ...............................................................................6ENGINE LUBRICATION CIRCUIT .........................................................6ENGINE LUBRICATION FLOW CHART ...............................................6OIL PRESSURE .............................................................................................6OIL FILTER ....................................................................................................6OIL STRAINER ..............................................................................................6OIL PUMP ......................................................................................................6-

2
2
4
5
5
5
5

6-2

LUBRICATION SYSTEM

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ENGINE LUBRICATION CIRCUIT

OIL PUMP

OIL FILTER

LUBRICATION OIL
RETURNED OIL

LUBRICATION SYSTEM

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EXHAUST SIDE

INTAKE SIDE

LUBRICATION OIL
RETURNED OIL

6-3

DRIVESHAFT
RIGHT END
BEARING

DRIVESHAFT
BUSHINGS/
GEARS

OIL JET

CLUTCH
RELEASE
BEARING
CAMSHAFT
JOURNAL (L)

CRANKSHAFT
RIGHT END
BEARING

CYLINDER
WALL &
PISTON

ROCKER
ARMS &
SHAFTS

CLUTCH COVER

CAM DRIVE
CHAIN

OIL SUMP
FILTER

OIL PUMP

OIL FILTER

ORIFICE

REVERSE IDLE
SHAFT

COUNTERSHAFT
LEFT END
BEARING

COUNTERSHAFT
BUSHINGS/GEARS

CYLINDER

CAMSHAFT
JOURNAL (R)

CAM FACE
(IN & EX)

CLUTCH
SHOE
HOUSING
BUSHING

CONROD
SMALL END

ORIFICE

CLUTCH
SHOE

ONE-WAY
CLUTCH

CRANKSHAFT(R)

CONROD
BIG END
BEARING

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PRIMARY
DRIVEN GEAR
BUSHING

CLUTCH
PLATES

6-4
LUBRICATION SYSTEM

ENGINE LUBRICATION FLOW CHART

LUBRICATION SYSTEM

OIL PRESSURE
(!2-25)

OIL FILTER
(!2-10)

OIL STRAINER
(!3-20, -61 and -62)

OIL PUMP

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(!3-18 and -64)

6-5

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CHASSIS

7-1

CHASSIS

CONTENTS

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EXTERIOR PARTS ........................................................................................7- 3
CONSTRUCTION ....................................................................................7- 3
REMOVAL ...............................................................................................7- 5
REMOUNTING ........................................................................................7- 8
FRONT AND REAR WHEELS.......................................................................7-10
CONSTRUCTION ....................................................................................7-10
REMOVAL ...............................................................................................7-11
INSPECTION AND DISASSEMBLY .......................................................7-12
REASSEMBLY AND REMOUNTING......................................................7-13
TIRES .............................................................................................................7-16
TIRE REPLACEMENT ............................................................................7-16
FRONT BRAKE .............................................................................................7-18
CONSTRUCTION ....................................................................................7-18
BRAKE PAD REPLACEMENT ...............................................................7-19
BRAKE FLUID REPLACEMENT ............................................................7-19
BRAKE CALIPER REMOVAL AND DISASSEMBLY.............................7-20
BRAKE CALIPER INSPECTION ............................................................7-21
BRAKE CALIPER REASSEMBLY AND REMOUNTING .......................7-23
BRAKE DISC REMOVAL AND DISASSEMBLY ....................................7-24
BRAKE DISC INSPECTION....................................................................7-25
BRAKE DISC REASSEMBLY AND REMOUNTING ..............................7-25
MASTER CYLINDER REMOVAL AND DISASSEMBLY........................7-26
MASTER CYLINDER INSPECTION .......................................................7-27
MASTER CYLINDER REASSEMBLY AND REMOUNTING ..................7-27
FRONT SUSPENSION ..................................................................................7-29
CONSTRUCTION ....................................................................................7-29
REMOVAL AND DISASSEMBLY ...........................................................7-30
INSPECTION ...........................................................................................7-31
REASSEMBLY AND REMOUNTING......................................................7-33
SUSPENSION SETTING .........................................................................7-34
STEERING .....................................................................................................7-35
CONSTRUCTION ....................................................................................7-35
REMOVAL ...............................................................................................7-36
INSPECTION AND DISASSEMBLY .......................................................7-38
REASSEMBLY AND REMOUNTING......................................................7-40
TOE-IN ADJUSTMENT ...........................................................................7-43
FRONT WHEEL, FRONT BRAKE, FRONT SUSPENSION AND
STEERING REASSEMBLING INFORMATION.............................................7-44

CHASSIS

CONTENTS

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REAR BRAKE ............................................................................................... 7-45
CONSTRUCTION ................................................................................... 7-45
REMOVAL AND DISASSEMBLY........................................................... 7-46
INSPECTION .......................................................................................... 7-48
REASSEMBLY AND REMOUNTING ..................................................... 7-49
REAR SHOCK ABSORBER ......................................................................... 7-53
CONSTRUCTION ................................................................................... 7-53
REMOVAL .............................................................................................. 7-53
INSPECTION .......................................................................................... 7-53
REASSEMBLY ....................................................................................... 7-54
REMOUNTING ........................................................................................ 7-54
SUSPENSION SETTING ........................................................................ 7-55
REAR SHOCK ABSORBER DISPOSAL ............................................... 7-55
REAR SUSPENSION .................................................................................... 7-56
CONSTRUCTION ................................................................................... 7-56
REMOVAL .............................................................................................. 7-57
INSPECTION AND DISASSEMBLY....................................................... 7-57
REASSEMBLY ....................................................................................... 7-58
REMOUNTING ........................................................................................ 7-59
REAR AXLE .................................................................................................. 7-60
CONSTRUCTION ................................................................................... 7-60
REMOVAL .............................................................................................. 7-61
INSPECTION .......................................................................................... 7-61
REASSEMBLY AND REMOUNTING ..................................................... 7-62
REAR WHEEL, REAR BRAKE, REAR SUSPENSION, REAR SWINGARM
AND REAR AXLE SHAFT REASSEMBLING INFORMATION ........................ 7-63
REVERSE LOCK RELEASE CABLE ........................................................... 7-64
REMOVAL .............................................................................................. 7-64
REMOUNTING ........................................................................................ 7-65

7-2

CHASSIS

EXTERIOR PARTS

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86

CONSTRUCTION

1 Front fender
2 Fuel tank top cover
3 Fuel tank side cover
4 Front fender bracket
5 Headlight case

7-3

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m
86

CHASSIS

7-4

1 Rear fender
2 Rear fender cover
3 Footrest mud guard

CHASSIS

REMOVAL
SEAT
Remove the seat by pulling the lever.

8 7 tS
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m
86

FRONT GRIP BAR
Remove the front grip bar 1.

REAR GRIP BAR
Remove the rear grip bar 1.

FUEL TANK SIDE COVER
Remove the seat. (!Above)
Remove the fuel tank side covers 1 and 2.

7-5

7-6

CHASSIS

FRONT FENDER
Remove the fuel tank side covers. (!7-5)
Remove the screws and fasteners.

8 7 tS
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m
86

Open the fuel tank cap and remove the fuel tank top cover 1.

Remove the reverse lock release knob 2.

Remove the screws that connect the front fender with the
head light.
Remove the front fender.

CHASSIS

8 7 tS
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m
86

FOOTREST MUD GUARD
Remove the fuel tank side covers. (!7-5)
Remove the footrest mud guards 1 and 2.

FOOTREST
Remove the footrest mud guards. (!Above)
Remove the footrest 1 and 2.

REAR FENDER
Remove the fuel tank side covers. (!7-5)
Remove the battery holder 1 and battery.

7-7

7-8

CHASSIS

Remove the screws.
Pull out the taillight assembly 2 with the bracket.

8 7 tS
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m
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Remove the rear fender mounting bolts.

Remove the footrest mud guards.
Remove the rear fender.

REMOUNTING

Remount the exterior parts in the reverse order of removal. Pay
attention to the following points:

FRONT GRIP BAR
Tighten the front grip bar mounting bolts to the specified
torque.
" Front grip bar mounting bolt:
26 N•m (2.6 kgf-m, 19.0 lb-ft)
REAR GRIP BAR
Tighten the rear grip bar mounting bolts to the specified
torque of each.
" Rear grip bar mounting bolt 1:
28 N•m (2.8 kgf-m, 20.5 lb-ft)
2:
55 N•m (5.5 kgf-m, 40.0 lb-ft)

CHASSIS

FOOTREST
Apply THREAD LOCK to the bolts A and tighten each bolt to
the specified torque.
# 99000-32050: THREAD LOCK 1342

8 7 tS
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m
86

" Footrest mounting bolt A: 55 N•m (5.5 kgf-m, 40.0 lb-ft)
Footrest mounting bolt B: 26 N•m (2.6 kgf-m, 19.0 lb-ft)

7-9

7-10

CHASSIS

FRONT AND REAR WHEELS
CONSTRUCTION

8 7 tS
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m
86

1 Front brake disc
2 Spacer
3 Dust seal
4 Bearing
5 Spacer
6 Front wheel Hub
7 Rear wheel Hub
8 Hub plate
9 Disc cover

@
ITEM

A
B
C
D

N•m

kgf-m

lb-ft

2.3

16.5

5.0

36.0

6.5

47.0

138

13.8

99.9

CHASSIS

REMOVAL
FRONT AND REAR WHEELS
Place the vehicle on the level ground.
Support the vehicle with a jack or wooden block.
Remove the wheel.

8 7 tS
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m
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FRONT WHEEL HUB
Remove the front wheel. (!Above)
Remove the front hub plate 1.
Remove the cotter pin and loosen the wheel hub nut with
applying the front brake.
Remove the wheel hub nut and washer.
Remove the front brake caliper. (!7-20)
Remove the front wheel hub 2.

Do not operate the front brake lever while the caliper
is removed.

Remove the spacer 3.
Remove the brake disc. (!7-24)

REAR WHEEL HUB
Remove the rear wheel. (!7-11)
Remove the rear hub plate 1. (RH only)
Remove the cotter pin and loosen the wheel hub nut with
applying the rear brake.
Remove the wheel hub nut and washer.
Remove the wheel hub 2.

7-11

7-12

CHASSIS

INSPECTION AND DISASSEMBLY
DUST SEAL
Inspect the dust seal lips for wear or damage.
If any damages are found, replace the dust seal with a new one.

8 7 tS
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m
86

Remove the dust seals with the special tool.
% 09913-50121: Oil seal remover
$

Replace the removed dust seals with new ones.

HUB BEARINGS
Inspect the inner race play of the hub bearing by hand while it is
in the wheel hub.
Rotate the inner race by hand to inspect for abnormal noise and
smooth rotation. If there is anything unusual, replace the bearing
with a new one.

Remove the hub bearings with the special tool.

% 09921-20240: Bearing remover set
$

Never reuse the removed bearings.

CHASSIS

REASSEMBLY AND REMOUNTING
FRONT WHEEL HUB
Apply SUZUKI SUPER GREASE to the hub bearings and the
lips of the dust seals before installing them.
& 99000-25030: SUZUKI SUPER GREASE A ( USA)
99000-25010: SUZUKI SUPER GREASE A ( Others)
Install the hub bearings and spacer into the front wheel hub.
% 09913-70210: Bearing installer set
09924-84510: Bearing installer set

8 7 tS
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86

NOTE:
Install the inner bearing 1 and the spacer 2 first, and then
install the outer bearing 3. Make sure the sealed side of the
bearing faces the bearing installer.

Install the dust seals into the front wheel hub with stamped
mark facing outside with the special tool.

% 09913-70210: Bearing installer set

Apply SUZUKI SUPER GREASE to the dust seal lips.

& 99000-25030: SUZUKI SUPER GREASE A ( USA)
99000-25010: SUZUKI SUPER GREASE A (Others)
Install the brake disc. (!7-25)

7-13

7-14

CHASSIS

Install the spacer 4 to the front wheel hub.

8 7 tS
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m
86

Install the front wheel hub to the front axle 5.
Install the front brake caliper. (!7-24)

Tighten the front wheel hub nut to the specified torque.
" Front wheel hub nut: 65 N•m (6.5 kgf-m, 47.0 lb-ft)
Install the cotter pin into the front axle as shown.
Install the front hub plate.
Install the front wheel. (!7-15)
$

Replace the removed cotter pin with a new one.

REAR WHEEL HUB
Apply small amount of SUZUKI SUPER GREASE to the left
rear wheel hub s spline.
& 99000-25030: SUZUKI SUPER GREASE A ( USA)
99000-25010: SUZUKI SUPER GREASE A (Others)

Apply detergent to the O-ring 1 and install it to the right rear
wheel hub.
NOTE:
Check the O-ring before installing. If abnormal, change the O-ring
with a new one.
$
Do not apply grease to the right rear wheel hub s
spline.

CHASSIS

Install the rear wheel hub and washer.
NOTE:
The convex side of the washer faces outside.
INSIDE
OUTSIDE

8 7 tS
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m
86

Washer

Tighten the rear wheel hub nut to the specified torque.

" Rear wheel hub nut: 138 N•m (13.8 kgf-m, 99.9 lb-ft)
Install the cotter pin into the rear axle as shown.
Install the rear hub plate. (RH only)
Install the rear wheel. (!Below)
$

Replace the removed cotter pin with a new one.

FRONT WHEEL
Tighten the front wheel set nuts to the specified torque.
" Front wheel set nut: 50 N•m (5.0 kgf-m, 36.0 lb-ft)

NOTE:
When installing the front wheel, make sure that the arrow A on
the tire points in the direction of rotation.

REAR WHEEL
Tighten the rear wheel set nuts to the specified torque.
" Rear wheel set nut: 50 N•m (5.0 kgf-m, 36.0 lb-ft)

NOTE:
When installing the rear wheel, make sure that the instruction
SIDE FACING OUTWARDS B on the rear tire faces outwards.

7-15

7-16

CHASSIS

TIRES
TIRE REPLACEMENT

8 7 tS
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m
86

Remove the front and rear wheels. (!7-11)
After removing the air valve cap, release the tire pressure by
depressing the valve.
Dismount the bead from the rim completely as shown.

Separate the tire from the rim by using a set of tire levers and
rim protectors.
$

When using the tire lever, do not scratch or hit the
sealing portion (hump) of the wheel or it may cause
air-leakage.

Apply tire lubricant to the tire bead and the flange of the rim.
$

Never apply grease, oil or gasoline to the tire bead
because they will deteriorate the tire.

The standard tire fitted on this vehicle is AT22 × 7-10
✩✩ for the front and AT20 × 10-9 ✩ for the rear.
The use of tires other than the standard may cause
instability. It is highly recommended to use the specified tire.
Mount the tire on the rim.

NOTE:
Inspect the sealing portion of the rim for contamination and distortion before installing the tire on the rim.

CHASSIS

When installing each tire, make sure the arrow A on the tire
points in the direction of rotation. Also, make sure the outer
side of the wheel rim is facing outward.
NOTE:
For inspecting the tire refer to page 2-17.
Inspect the valve core, before installation.

8 7 tS
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Inflate the tire to seat the tire bead.
' Maximum tire bead seat pressure
Front and rear: 250 kPa (2.5 kgf/cm2, 36 psi)
$

Place the tire under a protective tire cage or similar
protective covering device before inflating the tire. To
minimize the possibility of tire damage when seating
the tire bead, never exceed the MAXIMUM TIRE BEAD
SEAT PRESSURE rating shown on the tire.

NOTE:
Check the rim line 1 cast on the tire side walls. It must be
equidistant from the wheel rim all the way around. If the distance
between the rim line and the wheel rim varies this indicates that
the bead is not properly seated. If this is so, deflate the tire completely, and unseat the tire bead on both sides. Then, coat the
bead with clean water, and re-seat the tire.

Adjust the tire pressure to specification. (!2-18)
$

Before inflating the tire, check the MAXIMUM OPERATING PRESSURE rating of the tire. This is indicated
by a ✩ following the tire size shown on the sidewall.
The number of ✩ on the tire indicates the maximum
operating pressure.

' Maximum operating pressure
✩: 25 kPa (0.25 kgf/cm2, 3.6 psi)
✩✩:
✩✩ 35 kPa (0.35 kgf/cm2, 5.1 psi)
✩✩✩:
✩✩✩ 45 kPa (0.45 kgf/cm2, 6.5 psi)

7-17

7-18

CHASSIS

FRONT BRAKE
CONSTRUCTION

@
A
B
C
D
E
F
G
H
I

N•m

kgf-m

lb-ft

1.0

7.0

2.3

16.5

0.6

4.4

2.6

19.0

1.8

13.0

1.8

13.0

2.3

16.5

2.3

16.5

1.6

11.6

8 7 tS
7- h
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m
86

ITEM

A Master cylinder mounting bolt
B Brake hose union bolt
C Air bleeder valve
D Brake caliper mounting bolt
E Brake pad mounting pin
F Caliper holder pin
G Caliper holder slide pin
H Brake disc bolt
I Brake pipe nut

1 Master cylinder reservior cap
2 Diaphragm
3 Master cylinder clamp
4 Boot
5 Piston/cup set
6 Cup
7 Spring
8 Master cylinder
9 Brake hose No. 1
0 Piston
A Piston seal
B Dust seal
C Brake caliper
D Brake caliper holder
E Brake pad
F Pad spring
G Disc cover
H Front brake disc
I Brake pipe
J Brake hose No. 2

(

* This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix
different types of fluid, such as silicone-based or petroleum-based brake fluids.
* Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake
fluid left over from the last servicing or which has been stored for a long periods of time.
* When storing brake fluid, seal the container completely and keep it away from children.
* When replenishing brake fluid, take care not to get dust into the fluid.
* When washing brake components, use new brake fluid. Never use cleaning solvent.
* A contaminated brake disc or brake pad reduces braking performance. Discard contaminated
pads and clean the brake disc with high quality brake cleaner or a neutral detergent.
$
Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials
etc. and will damage them severely.

CHASSIS

BRAKE PAD REPLACEMENT
Remove the front wheel. (!7-11)
Remove the brake caliper mounting bolts 1 and brake pad
mounting pins 2.

8 7 tS
7- h
99 ar
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m
86

Remove the brake pads.

* Do not operate the brake lever during or after brake
pad removal.
* Replace the brake pads as a set, otherwise braking
performance will be adversely affected.
Install the new brake pads.

NOTE:
The shim must be installed to the caliper piston side pad.

Tighten the brake pad mounting pins 3 and brake caliper
mounting bolts 4 to the specified torque.
" Brake pad mounting pin: 18 N•m (1.8 kgf-m, 13.0 lb-ft)
Brake caliper mounting bolt:
26 N•m (2.6 kgf-m, 19.0 lb-ft)

NOTE:
After replacing the brake pads, pump the brake lever a few times
to check for proper brake operation and then check the brake
fluid level.

BRAKE FLUID REPLACEMENT

Place the vehicle 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 new brake fluid.

) Specification and classification: DOT 4

7-19

7-20

CHASSIS

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.
" Brake air bleeder valve: 6.0 N•m (0.6 kgf-m, 4.4 lb-ft)

8 7 tS
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$
* Never reuse the brake fluid left over from previous
servicing and which has been stored for long periods of time.
* Bleed air from the brake system.
(!2-16)

BRAKE CALIPER REMOVAL AND
DISASSEMBLY

Remove the front wheel. (!7-11)
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.
Remove the brake caliper by removing the brake caliper
mounting bolts 2.
Remove the brake pads. (!7-19)
(

Brake fluid, if it leaks, will interfere with safe running
and discolor painted surfaces. Check the brake hose,
brake pipe and hose joints for cracks and oil leakage.
Remove the spring 3.

CHASSIS

Place a rag over the brake caliper piston to prevent the piston
from popping out and then force out the piston using compressed air.
$
Do not use high pressure air to prevent brake caliper
piston damage.

8 7 tS
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m
86

Remove the dust seal and piston seal.

Do not reuse the dust seal and piston seal to prevent
fluid leakage.

Remove the cap 4 and loosen the brake caliper holder slide
pin 5.
Remove the brake caliper holder 6.

Remove the brake caliper holder slide pin 7.

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.

7-21

7-22

CHASSIS

BRAKE CALIPER PISTON
Inspect the brake caliper piston for any scratches or other damage. If any damages are found, replace the piston with a new
one.

8 7 tS
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m
86

RUBBER PARTS
Inspect the rubber parts for damage. If any damages are found,
replace them with new ones.

CALIPER HOLDER
Inspect the caliper holder 1 and pin 2 for damage. If any damages are found, replace them with new ones.

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 bore and piston with the specified brake
fluid. Thoroughly wash the dust seal grooves and piston seal
grooves.
) Specification and classification: DOT 4

8 7 tS
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m
86

$
* Wash the brake caliper components with new brake
fluid before reassembly.
* Do not wipe the brake fluid off with a rag 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.
* 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.

PISTON SEAL
Install the piston seal 1 and dust seal 2 as shown.

BRAKE CALIPER HOLDER
Tighten the pin 2 to the caliper holder 1 to the specified
torque.
" Caliper holder pin: 18 N•m (1.8 kgf-m, 13.0 lb-ft)

Apply SUZUKI SILICONE GREASE to the brake caliper
holder pin 2.
* 99000-25100: SUZUKI SILICONE GREASE

7-23

7-24

CHASSIS

Apply SUZUKI SILICONE GREASE to the brake caliper
holder slide pin.
* 99000-25100: SUZUKI SILICONE GREASE

8 7 tS
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m
86

Install the pin 1, washer 2 and caliper holder 3 to the caliper.
Apply THREAD LOCK SUPER to the pin 1.
+ 99000-32130: THREAD LOCK SUPER 1360
Tighten the pin 1 to the specified torque.

" Caliper holder slide pin: 23 N•m (2.3 kgf-m, 16.5 lb-ft)
Install the pads and spring to the caliper.

Tighten the brake pad mounting pins 4, brake caliper mounting bolts 5 and brake hose union bolt 6 to the specified
torque.
" Brake pad mounting pin: 18 N•m (1.8 kgf-m, 13.0 lb-ft)
Brake caliper mounting bolt:
26 N•m (2.6 kgf-m, 19.0 lb-ft)
Brake hose union bolt: 23 N•m (2.3 kgf-m, 16.5 lb-ft)

NOTE:
Before remounting the brake caliper, push the brake caliper pistons all the way into the caliper.

Bleed air from the system after reassembling the
brake caliper. (!2-16)

BRAKE DISC REMOVAL AND
DISASSEMBLY
Remove the front wheel hub. (!7-11)
Remove the brake disc.

CHASSIS

BRAKE DISC INSPECTION
Remove the front wheel. (!7-10)
Remove the caliper. (!7-19)
Inspect the brake disc for cracks or damage and measure the
thickness using the micrometer. If any damages are found or if
the thickness is less than the service limit, replace the brake disc
with a new one.
% 09900-20205: Micrometer (0

25 mm)

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m
86

' Brake disc thickness
Service Limit: 2.5 mm (0.098 in)
Measure the runout using the dial gauge. If the runout exceeds
the service limit, replace the brake disc with a new one.
% 09900-20607: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
' Brake disc runout
Service Limit: 0.3 mm (0.012 in)

If either measurement exceeds the service limit, replace the
brake disc with a new one.

BRAKE DISC REASSEMBLY AND
REMOUNTING

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

Install the disc to the wheel hub with the punching letters A
on the disc showed up.
NOTE:
Make sure that the disc is clean and free of any greasy matter.

Apply THREAD LOCK SUPER to the brake disc bolts and
tighten them to the specified torque.

+ 99000-32130: THREAD LOCK SUPER 1360
" Brake disc bolt: 23 N•m (2.3 kgf-m, 16.5 lb-ft)
Install the front wheel hub. (!7-14)
Install the front wheel. (!7-15)

7-25

7-26

CHASSIS

MASTER CYLINDER REMOVAL AND
DISASSEMBLY
Place a rag underneath the brake hose union bolt on the master cylinder to catch any split brake fluid. Remove the brake
hose union bolt and disconnect the brake hose.

8 7 tS
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m
86

$
Immediately wipe off any brake fluid contacting any
part of the vehicle. The brake fluid reacts chemically
with paint, plastics, rubber materials, etc., and will
damage them severely.
Remove the master cylinder assembly.
Disconnect the brake switch coupler.

Remove the brake lever 1 and brake switch 2.

Remove the reservoir cap 3 and diaphragm 4 from the
master cylinder.
Drain the brake fluid.

Pull the dust boot 5 out and remove the snap ring 6.

CHASSIS

Remove the piston/secondary cup, primary cup and spring.
7
8
9
0

Secondary cup
Piston
Primary cup
Spring

8 7 tS
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m
86

MASTER CYLINDER INSPECTION
MASTER CYLINDER
Inspect the master cylinder bore for any scratches or damage. If
any damages are found, replace the master cylinder with a new
one.

PISTON AND RUBBER PARTS
Inspect the piston surface, primary cup, secondary cup and dust
boot for any scratches, wear or damage. If any damages are
found, replace them with a new one.

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 with a rag 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
the component to be inserted to the bore.
) Specification and classification: DOT 4

7-27

7-28

CHASSIS

Align the master cylinder holder s mating surface 1 with the
punched mark 2 on the handlebars and tighten the upper
clamp bolt first.
" Master cylinder clamp bolt: 10 N•m (1.0 kgf-m, 7.0 lb-ft)

Master cylinder
Master cylinder upper clamp bolt
Handlebar
Clearance

8 7 tS
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m
86

A
B
C
D

Tighten the brake hose union bolt 3 to the specified torque.
" Brake hose union bolt: 23 N•m (2.3 kgf-m, 16.5 lb-ft)

NOTE:
After the brake hose union touching to the stopper, tighten the
union bolt.
$

Bleed air from the brake system after reassembling
the master cylinder. (!2-16)

CHASSIS

7-29

FRONT SUSPENSION
CONSTRUCTION

8 7 tS
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m
86

1 Front shock absorber
2 Upper wishbone arm
3 Bushing
4 Lower wishbone arm
5 Steering knuckle
6 Snap ring
7 Knuckle end
A Shock absorber mounting upper nut
B Shock absorber mounting lower nut
C Wishbone arm pivot nut
D Steering knuckle nut
E Tie rod end nut

@
ITEM

AB
C
DE

N•m

kgf.m

lb-ft

6.0

43.5

6.5

47.0

2.9

21.0

7-30

CHASSIS

REMOVAL AND DISASSEMBLY
Remove the wheel hub. (!7-11)
Remove the brake hose clamp 1.
Disconnect the brake hose from the brake hose clamp 2.

8 7 tS
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m
86

Remove the front disc cover 3.

Remove the cotter pin, tie rod end nut and washer.

Disconnect the tie rod end with a commercially available ball
bearing joint remover 4.

Remove the shock absorber lower mounting bolt 5.
Remove the wishbone arm assembly 6.

CHASSIS

Remove the front shock absorber 7.

8 7 tS
7- h
99 ar
k
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56 o
m
86

Remove the cotter pins, knuckle nuts and washers.

Disconnect the steering knuckle 8 with a commercially available ball bearing joint remover.

INSPECTION

FRONT SHOCK ABSORBER
Inspect the shock absorber for oil leakage or damage. If any
damages are found, replace the front shock absorber with a new
one.

Inspect the rubber bushing for wear or damage.
If any damages are found, replace the shock absorber with a
new one.

7-31

7-32

CHASSIS

KNUCKLE
Inspect the knuckle for damage. If any damages are found,
replace the knuckle with a new one.

8 7 tS
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86

KNUCKLE END
Inspect the knuckle end boots for wear or damage. If any damages are found, replace the wishbone arm with a new one.

WISHBONE ARM
Inspect the wishbone arms for wear or damage. If any damages
are found, replace the wishbone arm with a new one.

Inspect the rubber bushing for wear or damage. If any damages
are found, replace the bushing with a new one.

BRAKE DISC COVER
Inspect the brake disc cover for damage. If any damages are
found, replace the brake disc cover with a new one.

CHASSIS

REASSEMBLY AND REMOUNTING
Reassemble and remount the front suspension in the reverse
order of removal and disassembly. Pay attention to the following
points:

8 7 tS
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m
86

Degrease the tapered portions of the knuckle, knuckle end
and tie rod end with nonflammable cleaning solvent.

Install the wishbone arms to the knuckle.
Install the washers and tighten the knuckle nuts to the specified torque.
" Knuckle nut: 29 N•m (2.9 kgf-m, 21.0 lb-ft)
Install new cotter pins.

Replace the removed cotter pins with new ones.

Install the front shock absorber 1.

7-33

7-34

CHASSIS

Apply THREAD LOCK SUPER to the wishbone arm pivot
bolts 3.
Tghten the upper and lower front shock absorber mounting
nuts 2 and the wishbone arm pivot nuts 3 to the specified
torque.
, 99000-32030: THREAD LOCK SUPER 1303 (USA)
- 99000-32110: THREAD LOCK SUPER 1322 (Others)

8 7 tS
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m
86

" Wishbone arm pivot nut: 65 N•m (6.5 kgf-m, 47.0 lb-ft)
Shock absorber upper mounting nut:
60 N•m (6.0 kgf-m, 43.5 lb-ft)
Install the washer and tighten the tie rod end nut to the specified torque.
" Tie rod end nut: 29 N•m (2.9 kgf-m, 21 lb-ft)
Install new cotter pin.
$

Replace the removed cotter pin with a new one.

Apply THREAD LOCK SUPER to the disc cover mounting
bolts, and then tighten the bolts.

+ 99000-32130: THREAD LOCK SUPER 1360

SUSPENSION SETTING

SPRING PRE-LOAD ADJUSTMENT
After installing the rear suspension, adjust the spring pre-load.
Position 1 provides the softest spring pre-load.
Position 5 provides the stiffest spring pre-load.
STD POSITION: 2
(
Be sure to adjust the spring pre-load on the both suspensions equally.

CHASSIS

STEERING
CONSTRUCTION

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1 Steering head cover
2 Handlebars
3 Handlebar upper clamp
4 Handlebar lower clamp
5 Brake cable guide
6 Steering shaft holder
7 Steering shaft
8 Dust seal
9 Bushing
0 Dust seal
A O-ring
B Dust seal
C Tie rod
D Tie rod end
A Handlebar clamp bolt
B Steering shaft holder bolt
C Steering shaft nut
D Tie rod end nut
E Tie rod locknut

@
ITEM

A
B
C
D
E

N•m

kgf-m

lb-ft

2.3

16.5

2.3

16.5

4.9

35.5

2.9

21.0

2.9

21.0

7-35

7-36

CHASSIS

REMOVAL
Remove the front fender. (!7-6)
Remove the master cylinder assembly 1 from the handlebars. (!7-26)
Remove the throttle lever case 2.

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86

Disconnect the rear brake cable 3 and remove the handlebar
switch 4.

Disconnect the fuel vent hose and remove the steering head
cover 5.

Disconnect the indicator lights 6 from the steering head
cover.
Remove the clamps 7.
Remove the handlebars 8.

Remove the cotter pins, tie rod end nuts and washers.
$
Replace the removed cotter pins with new ones.

CHASSIS

Remove the tie rod ends with a commercially available ball
bearing joint remover.

8 7 tS
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m
86

Remove the cotter pin and steering shaft nut 9, washer 0
and dust seal A.

Replace the removed cotter pins with new ones.

Remove the O-ring B.

Remove the steering shaft holder bolts.
Remove the steering shaft holder half.

Remove the steering shaft C.
Remove the dust seals D from the steering shaft.
Remove the steering shaft holder half E.

7-37

7-38

CHASSIS

Remove the steering shaft.
Remove the dust seal F from the steering shaft.

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m
86

INSPECTION AND DISASSEMBLY
Inspect the removed parts for the following abnormalities.
* Handlebar distortion
* Handlebar clamp wear

DUST SEALS AND O-RING
Inspect the dust seals and O-ring for wear or damage. If any
damages are found, replace the dust seals with new ones.

Tie rod end
Locknut
Locknut
Tie rod

1
2
3
4

TIE ROD
Inspect the tie rod for distortion or damage. If any damages are
found, replace the tie rod with a new one.

The locknuts 2 with a yellow finished surface have
left-hand threads.

TIE ROD END
Inspect the tie rod ends for smooth movement. If there are any
abnormalities, replace the tie rod end with a new one.
Inspect the tie rod end boot for wear or damage.
If any damages are found, replace the tie rod end with a new
one.

CHASSIS

STEERING SHAFT
Inspect the steering shaft for distortion or bends. If any damages
are found, replace the steering shaft with a new one.

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m
86

STEERING SHAFT HOLDER
Inspect the two steering shaft holders for wear or damage. If any
damages are found, replace the steering shaft holders with new
ones.

STEERING SHAFT BUSHING
Inspect the steering shaft bushing 1 for wear and damage. If
any damages are found, replace it with a new one.

Remove the steering shaft bushing with the special tools.

% 09924-84510: Bearing installer set
09930-30721: Rotor remover

Install the steering shaft bushing with the special tool.
% 09924-84510: Bearing installer set

7-39

7-40

CHASSIS

REASSEMBLY AND REMOUNTING
Reassemble and remount the steering stem in the reverse order
of removal and disassembly. Pay attention to the following
points:
STEERING SHAFT
Apply SUZUKI SUPER GREASE to the O-ring, dust seals and
steering shaft before remounting the steering shaft.
& 99000-25030: SUZUKI SUPER GREASE A (USA)
99000-25010: SUZUKI SUPER GREASE A (Others)

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m
86

Install the dust seal 1 to the steering shaft.

Install the new O-ring 2 and dust seal to the steering shaft.

Tighten the steering shaft nut to the specified torque.
" Steering shaft nut: 49 N•m (4.9 kgf-m, 35.5 lb-ft)
$

Install new cotter pin.

Replace the removed cotter pin with a new one.

Apply SUZUKI SUPER GREASE to the steering shaft holders
and dust seals before remounting the steering shaft holders.
& 99000-25030: SUZUKI SUPER GREASE A (USA)
99000-25010: SUZUKI SUPER GREASE A (Others)
$
To prevent the entry of dirt, the dust seal end A must
face forward when installed to the steering shaft.

CHASSIS

Tighten the steering shaft holder bolts to the specified torque.
" Steering shaft holder bolt: 23 N•m (2.3 kgf-m, 16.5 lb-ft)
NOTE:
Make sure that the wiring harness, cables and brake hose routing are properly. (!9-12 to -14)

8 7 tS
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m
86

Degrease the tapered portions of the tie rod ends with nonflammable cleaning solvent.

TIE ROD
Install the washers and tighten the tie rod end nuts to the
specified torque.
" Tie rod end nut: 29 N•m (2.9 kgf-m, 21.0 lb-ft)
Install new cotter pins.
$

Replace the removed cotter pins with new ones.

NOTE:
When installing the tie rod, make sure the narrow end 1 of the
tie rod comes out.
$

The locknuts 2 with a yellow finished surface have
left-hand threads.

HANDLEBARS
When installing the lower handlebar holder 1 to the steering
shaft, the higher mating portion must face to forward.
Set the handlebars to match its punched mark 2 to the mating face of the handlebar clamps.
First tighten the bolts 3 to the specified torque and then
tighten the bolts 4 to the specified torque.
" Handlebar clamp bolt: 23 N•m (2.3 kgf-m, 16.5 lb-ft)

Forward

7-41

7-42

CHASSIS

Install the steering head cover with the projection A inserting
into the cushion B on the steering head cover bracket.
NOTE:
The indicator light position on the steering head cover is shown
on page 8-24.

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m
86

Install the handle switch with the lug 5 on the switch half
inserted into the hole 6 on the handlebars.

NOTE:
After installing the handlebars, make sure that the cable, wiring
harness and brake hose routing are properly. (!9-12 to -14)

Install the steering head cover.

CHASSIS

7-43

TOE-IN ADJUSTMENT
Adjust the toe-in as follows:
Place the vehicle on level ground and set the handlebars
straight.
Make sure all the tires are inflated to the standard pressure.
(!2-18)
Place 75 kg (165 lbs) of weight on the seat.
Loosen the locknuts (1, 2) on each tie rod.

Forward

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m
86

The locknuts 2 have left-hand threads.
Measure the distances (A and B) between the front wheels.
Subtract the measurements of A from the measurements of
B to find the toe-in. If the toe-in is not within specification,
adjust the tie rod to the right or left until the toe-in is within the
specified range.
A B = Toe-in
' Toe-in
Standard: 5 – 4 mm (0.20 – 0.16 in)

Temporarily tighten the four locknuts.
Check that the distances (C and D) are equal, as shown. If
the distances are not equal, adjust the tie rod to the right or
left until the toe-in is within specification. Check the toe-in
again by measuring distances A and B.
If the toe-in is not within specification, repeat the adjustment
as above until the proper toe-in is obtained and distances C
and D become equal.
After adjustment has been made, tighten the four locknuts 1
to the specified torque.

" Tie rod locknut: 29 N•m (2.9 kgf-m, 21.0 lb-ft)

Right angle
(90 deg.)

Forward

7
8
9
0
A
B

ITEM

kgf-m

6.0

6.5

2.9

5.0

6.5

2.3

N•m

16.5

47.0

36.0

21.0

47.0

43.5

lb-ft

kgf-m
2.3
4.9
2.9
6.0

N•m
23
49
29
60

Bend the cotter pin
securely.

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m
86

12
3
45
6

ITEM

43.5

21.0

35.5

16.5

lb-ft

7-44
CHASSIS

FRONT WHEEL, FRONT BRAKE, FRONT SUSPENSION AND
STEERING REASSEMBLING INFORMATION

CHASSIS

REAR BRAKE
CONSTRUCTION

8 Brake camshaft
9 O-ring
0 Brake lining indicator plate
A O-ring
B Brake panel
C Brake cam lever

A Brake panel nut
B Brake cam lever nut

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m
86

1 Dust seal
2 Drum cover
3 Brake drum
4 Brake shoe
5 O-ring
6 Snap ring
7 Bearing

@
ITEM

A
B
C

N•m

kgf-m

lb-ft

6.0

43.5

1.1

8.0

1.1

8.0

7-45

7-46

CHASSIS

REMOVAL AND DISASSEMBLY
Raise the rear wheel off the ground and support the vehicle
with a jack or wooden block.
Remove the right rear wheel hub. (!7-11)
Disconnect the brake cables.

8 7 tS
7- h
99 ar
k
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56 o
m
86

Remove the drum cover bolts.

Remove the drum cover 1 with a flat head screwdriver.
$

* Be careful not to distort the drum cover.
* Distortion of drum cover would cause a malfunction
of sealing.

Remove the brake drum 2.

Remove the brake shoes 3 and springs 4.
Remove the O-ring 5.
NOTE:
If reinstalling the removed brake shoes, mark the brake shoes
with direction (leading and trailing) of installation before removing the brake shoes.

CHASSIS

Disconnect the brake breather hose.
Remove the brake panel and panel cover 6.

8 7 tS
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m
86

Remove the O-ring 7.
Remove the brake cam lever 8.

Remove the brake lining indicator prate 9, washer 0 and
spring A.

Remove the brake camshaft B and O-rings C from the brake
panel.

7-47

7-48

CHASSIS

INSPECTION
BRAKE DRUM
Measure the brake drum s I.D. to determine the extent of wear. If
the measurement value exceeds the service limit, replace the
brake drum with a new one.
' Brake drum I.D.
Service Limit: 140.7 mm (5.54 in)

8 7 tS
7- h
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m
86

BRAKE SHOE
Inspect the brake shoes for wear or damage. If any wear or
damages are found, replace the brake shoes with new ones.

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

DUST SEAL
Inspect the dust seal on the drum cover for wear or damage.
If any damages are found, replace the dust seal with a new one.
$

Replace the removed dust seal with a new one.

BRAKE PANEL BEARING
Inspect the play of the brake panel bearing by hand while it is in
the brake panel. Rotate the inner race by hand to inspect for
abnormal noise and smooth rotation. Replace the bearing if
there is anything unusual.

Remove the snap ring.

CHASSIS

Remove the bearing with the special tool.
% 09921-20240: Bearing remover set
$
The removed bearing must be replaced with a new
one.

8 7 tS
7- h
99 ar
k
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56 o
m
86

REASSEMBLY AND REMOUNTING
Install new bearing with the special tool.
% 09913-70210: Bearing installer set

Install the snap ring.

Install new dust seal 2 to the drum cover 3 by using the
removed dust seal 1.

Apply SUZUKI SILICONE GREASE to the dust seal lips.
* 99000-25100: SUZUKI SILICONE GREASE

Dust seal
Drum cover

7-49

7-50

CHASSIS

Apply SUZUKI SUPER GREASE to new O-rings and brake
camshaft.
Install the O-rings and brake camshaft to the anchor panel.
& 99000-25030: SUZUKI SUPER GREASE A (USA)
99000-25010: SUZUKI SUPER GREASE A (Others)
$
O-rings should be replaced with new ones.

8 7 tS
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m
86

Install the washer 4.
Install the spring 5 with the spring end hocked to the hole on
the brake panel.

Align the protrusion A of the brake lining indicator prate 6
with the groove B of the brake camshaft.
Install the brake lining indicator prate 6.

Install the brake cam lever 7 as its punched mark C aligns
with the slit D on the brake camshaft.
Tighten the cam lever nut to the specified torque.
" Cam lever nut: 11 N•m (1.1 kgf-m, 8.0 lb-ft)

Install new O-ring 8 onto the rear brake panel.
$
O-ring must be replaced with a new one.

CHASSIS

Install the brake panel to the rear axle housing.
Install the panel cover 9.
Tighten the brake panel mounting nuts to the specified torque.
" Brake panel mounting nut: 60 N•m (6.0 kgf-m, 43.5 lb-ft)
Connect the brake breather hose.
NOTE:
Make sure that the O-ring 8 must be fitted into the groove on
the brake panel securely.

8 7 tS
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k
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m
86

Install new O-ring to the brake panel.

Replace the removed O-ring with a new one.

Apply SUZUKI SUPER GREASE to the anchor pin and brake
camshaft sliding surface lightly.
& 99000-25030: SUZUKI SUPER GREASE A (USA)
99000-25010: SUZUKI SUPER GREASE A (Others)
(

Be careful not to apply too much grease to the brake
camshaft and pin. If grease gets on the lining, brake
slippage will result.
Install the brake shoes and springs to the brake panel.

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

NOTE:
* When reinstalling the removed brake shoes, install them in
their original position, leading and trailing.
* Make sure that the brake shoe spring s end faces the brake
panel as shown.

7-51

7-52

CHASSIS

Install the brake drum.
$
Do not apply grease to the spline portion of brake
drum.
NOTE:
Before installing the brake drum, make sure that the brake drum
is clean and free of any greasey matter.

8 7 tS
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m
86

Install the drum cover and tighten the bolts.
NOTE:
When installing the drum cover, make sure that the O-ring must
be fitted into the groove on the brake panel securely.

NOTE:
Before connecting the brake cables, make sure that the
small-pitch portion of the cable spring faces to the cable adjuster
nut.

Connect the brake cables 0.

Install the right rear wheel hub. (!7-14)
Install the right rear wheel. (!7-15)
After installing the rear brake, adjust the following items.
* Brake pedal play ..... !2-14
* Brake lever play ...... !2-15

CHASSIS

REAR SHOCK ABSORBER
CONSTRUCTION

8 7 tS
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m
86

78 N•m (7.8 kgf-m, 55 lb-ft)

60 N•m (6.0 kgf-m, 43.0 lb-ft)

REMOVAL

Raise the rear wheel off the ground and support the vehicle
with a jack or wooden block.
Remove the rear shock absorber 1.

INSPECTION
REAR SHOCK ABSORBER
Inspect the rear shock absorber body and rubber bushing for
damage and leakage of oil.
If any defects are found, replace the rear shock absorber with a
new one.
$
Do not attempt to disassemble the rear shock
absorber and to bleed out the nitorogen gas. It is
unserviceble.

7-53

7-54

CHASSIS

REAR SHOCK ABSORBER SPACER AND BEARING
Remove the spacers and dust seals.
$
The removed dust seals must be replaced with new
ones.
Inspect the spacers for any flaws or other damage. If any damages are found, replace the spacers with new ones.

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Insert the spacer into the rear shock absorber bearing and
then check the play by moving the spacer up and down.
If excessive play is noted, replace the bearing with a new one.

Remove the rear shock absorber bearing with the special
tools.
% 09923-73210: Bearing remover
09930-30104: Sliding shaft
$

The removed bearing must be replaced with a new
one.

REASSEMBLY

REAR SHOCK ABSORBER
Press the bearing into the rear shock absorber to the depth of
4 mm (0.157 in) with the special tool and suitable socket
wrench.
NOTE:
When installing the rear shock absorber bearing, make sure that
the stamped mark faces right side.
% 09924-84521: Bearing installer set

REMOUNTING
Tighten the upper and lower shock absorber mounting nuts to
the specified torque of each.
" Rear shock absorber mounting nut (Upper):
78 N•m (7.8 kgf-m, 55 lb-ft)
Rear shock absorber mounting nut (Lower):
60 N•m (6.0 kgf-m, 43.0 lb-ft)

CHASSIS

SUSPENSION SETTING
SPRING PRE-LOAD ADJUSTMENT
The rear suspension spring pre-load is adjustable. This adjustment is performed by changing spring set length.
Loosen the locknut 1.
Adjust the spring set length by turning the adjuster 2.

MINIMUM
(STIFFEST)
227 mm
(8.94 in)

8 7 tS
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m
86

SPRING SET LENGTH A
MAXIMUM
STANDARD
(SOFTEST)
232.5 mm
235 mm
(9.15 in)
(9.25 in)

Do not set the spring length out of the specified range.
Tighten the locknut 1.

REAR SHOCK ABSORBER DISPOSAL
(

* The rear shock absorber unit contains high-pressure
nitrogen gas.
* Mishandling can cause explosion.
* Keep away from fire and heat. High gas pressure
caused by heat can cause an explosion.
* Release gas pressure before disposing.

GAS PRESSURE RELEASE
Remove the valve cap.
Press the valve with a screwdriver to bleed out the nitrogen
gas.
(

* Releasing high pressure gas from the rear shock
absorber unit can be hazardous. Never perform any
servicing until the nitrogen gas pressure has been
released from the rear shock absorber unit.
* When releasing the gas pressure, place a reg over
the gas valve and use the tip of a screwdriver to
press the valve. Do not use your finger to depress
the gas valve, and be sure to direct the valve away
from your face and body.
* Be sure to always wear eye protection when performing this procedure.

7-55

7-56

CHASSIS

REAR SUSPENSION
CONSTRUCTION

ITEM

N•m
78
60
85
60
65

kgf-m

lb-ft

7.8

55.0

6.0

43.5

8.5

61.5

6.0

43.5

6.5

47.0

A
B
C
D
EF

8 7 tS
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m
86

CHASSIS

REMOVAL
Remove the footrest mud guards. (!7-7)
Remove the rear drive gear case assembly. (!4-3)
Remove the rear shock absorber. (!7-53)

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Disconnect the brake breather hose 2 from the swingarm.
Loosen the swingarm pivot bolts/nuts 3.
Remove the swingarm.

INSPECTION AND DISASSEMBLY
REAR SHOCK ABSORBER
Inspect the rear shock absorber. (!7-53)

SPACER
Remove the dust covers 1 and spacers 2 from the swingarm.

Inspect the spacers 2 for any flaws or other damage. If any
defects are found, replace the spacer with a new one.

SWINGARM
Inspect the swingarm for distortion or damage. If any damage
are found, replace the swingarm with a new one.

7-57

7-58

CHASSIS

SWINGARM PIVOT BEARING
Insert the spacer into the swingarm pivot bearings and then
check the play by moving the spacer up and down.
If excessive play is noted, replace the bearing with a new one.

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Remove the swingarm pivot bearing with the special tools.
% 09923-74510: Bearing remover
09930-30104: Sliding shaft
$

The removed bearing must be replaced with a new
one.

REASSEMBLY

SWINGARM PIVOT BEARING AND DUST SEAL
Press the bearing into the swingarm pivot to the depth of 5.0
mm (0.197 in) from the outside with the special tool and suitable socket wrench.
NOTE:
When installing the swingarm pivot bearing, make sure that the
stamped mark faces outside.

% 09924-84510: Bearing installer set

Apply SUZUKI SUPER GREASE to the bearings, spacers
and ips of the dust covers.
& 99000-25030: SUZUKI SUPER GREASE A
99000-25010: SUZUKI SUPER GREASE A

(USA)
(Others)

Install the spacers and dust covers to the swingarm.

5.0 mm (0.197 in)

CHASSIS

REMOUNTING
Remount the rear swingarm and suspension in the reverse order
of removal. Pay attention to the following points:
Apply THREAD LOCK SUPER to the swingarm pivot bolts.
Install the swingarm pivot bolts and upper and lower shock
absorber mounting bolts temporarily.
Tighten the swingarm pivot nut to the specified torque.
, 99000-32030: THREAD LOCK SUPER 1303 (USA)
- 99000-32110: THREAD LOCK SUPER 1322 (Others)

8 7 tS
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m
86

" Swingarm pivot nut: 85 N•m (8.5 kgf-m, 61.5 lb-ft)

Tighten the upper and lower shock absorber mounting nuts to
the specified torque of each.

" Rear shock absorber mounting nut (Upper):
78 N•m (7.8 kgf-m, 55 lb-ft)
Rear shock absorber mounting nut (Lower):
60 N•m (6.0 kgf-m, 43.0 lb-ft)

7-59

7-60

CHASSIS

REAR AXLE
CONSTRUCTION

8 7 tS
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m
86

Do not apply grease
to the spline portion of the brake drum.

65 N•m (6.5 kgf-m, 47 lb-ft)

1 Rear axle
2 Rear axle housing

60 N•m (6.0 kgf-m, 43.5 lb-ft)

CHASSIS

REMOVAL
Remove the rear wheels. (!7-11)
Remove the rear wheel hubs. (!7-11)
Remove the rear brake. (!7-46)

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Remove the rear axle housing/final gear case bolts 1 and
rear axle housing set bolts/nuts 2.

Remove the rear axle housing 3 and rear axle 4.
Remove the O-ring 5.

INSPECTION

REAR AXLE SHAFT
Inspect the rear axle shaft visually for distortion or damages. If
any damages are found, replace the rear axle shaft with a new
one.

Using a dial gauge, check the axle shaft for runout and replace it
if the runout exceeds the limit.
" 09900-20607: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
09900-21304: V-block set (100 mm)
# Axle shaft runout
Service Limit: 3.0 mm (0.12 in)

7-61

7-62

CHASSIS

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REAR AXLE HOUSING
Inspect the rear axle housing for distortion or damages. If any
damages are found, replace the rear axle housing with a new
one.

REASSEMBLY AND REMOUNTING

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

Apply SUZUKI SUPER GREASE to the rear drive case spline.
& 99000-25030: SUZUKI SUPER GREASE A (USA)
99000-25010: SUZUKI SUPER GREASE A (Others)
Install new O-ring to the rear drive gear case.
NOTE:
Before installing the O-ring, apply grease to it.

Install the rear axle shaft and rear axle housing to the rear
drive gear case.

Apply THREAD LOCK SUPER to the rear axle housing/final
gear case bolts 1 and rear axle housing set bolts 2.
Tighten the rear axle housing/final gear case bolts 1 and rear
axle housing set nuts 2 to the specified torque of each.
, 99000-32030: THREAD LOCK SUPER 1303 (USA)

- 99000-32110: THREAD LOCK SUPER 1322 (Others)

" Rear axle housing/final gear case bolt:
65 N•m (6.5 kgf-m, 47.0 lb-ft)
Rear axle housing set nut:
60 N•m (6.0 kgf-m, 43.5 lb-ft)

Washer installing direction

5 mm
(0.20 in)

1
2
3
4
5
6
7
8
9

ITEM

25 mm
(0.98 in)

12 mm
(0.47 in)

8.5
7.8
6.0
6.0
5.0
13.8
1.1
6.0
6.5

78
60
60
50
138
11
60
65

kgf-m

N•m

47.0

43.5

8.0

96.6

36.0

43.5

56.0

61.5

lb-ft

11 N•m (1.1 kgf-m, 8.0 lb-ft)

Apply grease to the sliding part.

Do not apply grease.
Bend the cotter pin securely.

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5 mm
(0.20 in)

4 mm (0.16 in)

CHASSIS
7-63

REAR WHEEL, REAR BRAKE, REAR SUSPENSION, REAR SWINGARM AND REAR AXLE SHAFT REASSEMBLING INFORMATION

7-64

CHASSIS

REVERSE LOCK RELEASE CABLE
REMOVAL

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Remove the reverse lock release knob 1 from the front
fender.
Open the fixed clamp.

Remove the clip 2 and pin 3.
Loosen the locknuts 4 and remove the reverse lock release
cable.

Remove the bracket 5.

Remove the cap 6.

CHASSIS

Remove the screw 7 and washers 8.

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Remove the knob 9.
Disconnect the cable by removing the rotor 0.

REMOUNTING

Remount the reverse lock release cable in the reverse order of
removal. Pay attention to the following points:

Install the spring so that the spring end A matches the groove
B on the housing.

Apply SUZUKI SUPER GREASE to the O-ring 1.

& 99000-25030: SUZUKI SUPER GREASE A (USA)
99000-25010: SUZUKI SUPER GREASE A (Others)

Install the O-ring 1 to the reverse lock release cable 2.
Connect the cable to the rotor 3 through the hole of the housing.

NOTE:
* When installing the rotor, hook the spring end C on the concave portion D of the rotor.
* Make sure that the reverse lock release cable is routed correctly.

7-65

7-66

CHASSIS

CABLE PLAY ADJUSTMENT
After installing the reverse lock release cable, adjust the cable
play.

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Loosen the locknuts 1.
Slide the adjuster 2 until the cable play at the reverse lock
release knob A reaches 1 2 mm (0.04 0.08 in).
Tighten the locknuts 1 securely.

After adjustment, be sure to check for reverse lock function.

ELECTRICAL SYSTEM

8-1

ELECTRICAL SYSTEM

CONTENTS

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CAUTIONS IN SERVICING ..........................................................................8- 2
CONNECTORS .......................................................................................8- 2
COUPLERS .............................................................................................8- 2
CLAMPS ..................................................................................................8- 2
FUSES .....................................................................................................8- 2
SEMI-CONDUCTOR EQUIPPED PARTS ...............................................8- 2
BATTERY ................................................................................................8- 3
CONNECTING THE BATTERY...............................................................8- 3
WIRING PROCEDURE............................................................................8- 3
USING THE MULTI CIRCUIT TESTER...................................................8- 3
LOCATION OF ELECTRICAL COMPONENTS ...........................................8- 4
CHARGING SYSTEM ...................................................................................8- 6
TROUBLE SHOOTING ...........................................................................8- 6
INSPECTION ...........................................................................................8- 8
STARTER SYSTEM ......................................................................................8-11
TROUBLE SHOOTING ...........................................................................8-11
STARTER MOTOR REMOVAL AND DISASSEMBLY ...........................8-13
STARTER MOTOR INSPECTION...........................................................8-13
STARTER MOTOR REASSEMBLY AND REMOUNTING .....................8-14
STARTER RELAY INSPECTION............................................................8-15
NEUTRAL RELAY INSPECTION............................................................8-16
PARKING BRAKE SWITCH ...................................................................8-16
IGNITION SYSTEM .......................................................................................8-17
TROUBLESHOOTING ............................................................................8-17
INSPECTION ...........................................................................................8-19
LAMPS ..........................................................................................................8-22
HEADLIGHT ............................................................................................8-22
BRAKE LIGHT/TAILLIGHT.....................................................................8-23
INDICATOR LIGHT .......................................................................................8-24
INSPECTION ...........................................................................................8-24
INDICATOR LIGHT POSITION ...............................................................8-24
DIODE ...........................................................................................................8-25
SWITCHES ...................................................................................................8-26
BATTERY .....................................................................................................8-27
SPECIFICATIONS...................................................................................8-27
INITIAL CHARGING ................................................................................8-27
SERVICING .............................................................................................8-29
RECHARGING OPERATION ..................................................................8-29

8-2

ELECTRICAL SYSTEM

CAUTIONS IN SERVICING
CONNECTORS
When disconnecting a connector, be sure to hold the terminals; do not pull the lead wires.
When connecting a connector, push it in so it is firmly
attached.
Inspect the connector for corrosion, contamination and any
breakage in the cover.

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COUPLERS
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

FUSES

Refer to the WIRING HARNESS ROUTING section for
proper clamping procedures. (!9-11 to -14)
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 substitutes for the band-type clamp.

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).

SEMI-CONDUCTOR EQUIPPED PARTS
Do not drop any part that contains a semi-conductor (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.

INCORRECT

ELECTRICAL SYSTEM

BATTERY

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The MF battery used in this vehicle does not require maintenance (e.g., electrolyte level inspection, distilled water replenishment).
During normal charging, no hydrogen gas is produced. However, if the battery is overcharged, hydrogen gas may be produced. Therefore, be sure there are no fire or spark sources
(e.g., short circuit) nearby when charging the battery.
Be sure to recharge the battery in a well-ventilated and open
area.
Note that the charging system for the MF battery is different
from that of a conventional battery. Do not replace the MF
battery with a conventional battery.

CONNECTING THE BATTERY

When disconnecting terminals from the battery for disassembly or servicing, be sure to disconnect the - battery lead
wire, first.
When connecting the battery lead wires, be sure to connect
the + battery lead wire, first.
If the terminal is corroded, remove the battery, pour warm
water over it and clean it with a wire brush.
After connecting the battery, apply a light coat of grease to the
battery terminals.
Install the cover over the + battery terminal.

WIRING PROCEDURE

Properly route the wire harness according to the WIRING
HARNESS ROUTING section. (!9-11 to -14)

USING THE MULTI CIRCUIT TESTER

Properly use the multi circuit tester + and - probes.
Improper use can cause damage to the vehicle and tester.
If the voltage and current values are not known, begin measuring in the highest range.
When measuring the resistance, make sure 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.

8-3

8-4

ELECTRICAL SYSTEM

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LOCATION OF ELECTRICAL COMPONENTS

1
2
3
4
5
6
7

CDI unit
Battery
Fuse
Ignition switch
Front brake light switch
Rear brake light pedal switch
Starter motor

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ELECTRICAL SYSTEM

1
2
3
4
5
6

Handlebar switch (L)
Rear brake light switch
Parking brake switch
Neutral switch diode
Fuse
Starter relay

7
8
9
0
A

Ignition coil
Generator
Neutral switch
Regulator/rectifier
Neutral relay

8-5

8-6

ELECTRICAL SYSTEM

CHARGING SYSTEM
Ignition switch

Generator

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Battery

Regulator/rectifier

TROUBLE SHOOTING

Battery runs down quickly.
Step 1
1) Check accessories which use excessive amounts of electricity.
Are accessories being installed ?
Remove accessories
Go to Step 2.

YES
NO

Step 2
1) Check the battery for current leaks. (!8-8)
Is the battery for current leaks OK ?
YES
NO

Go to Step 3.
Short circuit of wire harness
Faulty electrical equipment

Step 3
1) Measure the regulated voltage between the battery terminals. (!8-8)
Is the battery charging of voltage OK ?
YES
NO

Faulty battery
Abnormal driving condition
Go to Step 4.

Load

Fuse

ELECTRICAL SYSTEM

Step 4
1) Measure the resistance of the generator coil. (!8-9)
Is the resistance of generator coil OK ?
YES
NO

Go to Step 5.
Faulty generator coil or disconnected lead wires

Step 5
1) Measure the generator no-load voltage. (!8-9)
Is the generator no-load voltage OK ?
Go to Step 6.
Faulty generator

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YES
NO

Step 6
1) Inspect the regulator/rectifier. (!8-10)
Is the regulator/rectifier OK ?
YES
NO

Go to Step 7.
Faulty regulator/rectifier

Step 7
1) Inspect the wirings.
Are the wirings OK ?
YES
NO

Faulty battery
Short circuit of wire harness
Poor contact of couplers

Battery overcharge
Faulty regulator/rectifier
Faulty battery
Poor contact of generator lead wire coupler

8-7

8-8

ELECTRICAL SYSTEM

INSPECTION
BATTERY CURRENT LEAKAGE
Remove the seat. (!7-5)
Turn the ignition switch to the OFF position.
Disconnect the - battery lead wire 1.
Measure the 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.
# Battery current (leak): Under 1.0 mA

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$ 09900-25008: Multi circuit tester set
% Tester knob indication: Current (&, 20 mA)
"

* Because the current leak might be large, turn the
tester to the high range first to avoid tester damage.
* Do not turn the ignition switch to the ON position
when measuring current.

DC mA

Battery

When checking to find the excessive current leakage, remove
the couplers and connectors, one by one, checking each part.

REGULATED VOLTAGE
Remove the seat. (!7-5)
Remove the battery holder 1.
Shift the transmission to the neutral position.
Start the engine, turn the ignition switch to LIGHT(') and the
dimmer switch to HI and run the engine at 5 000 r/min.

Measure the DC voltage between the + and - battery terminals using the multi circuit tester. If the voltage is not within the
specified value, inspect the generator and regulator/rectifier.
(!8-9 to -10)
NOTE:
When making this test, be sure that the battery is in fullycharged condition.
# Regulated voltage: 14.0

15.5 V at 5 000 r/min

$ 09900-25008: Multi circuit tester set
( Tester knob indication: Voltage (&)

DC V

ELECTRICAL SYSTEM

GENERATOR COIL RESISTANCE
Remove the left fuel tank side cover. (!7-5)
Disconnect the generator lead wire coupler.
Measure the resistance among the three lead wires.
If the resistance is not specified value, replace the stator coil
with a new one.
Also, check that the generator core is insulated.
# Generator coil resistance: 0.5 1.2 Ω
(Yellow Yellow)
∞ Ω (Yellow Ground)

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$ 09900-25008: Multi circuit tester set

) Tester knob indication: Resistance (Ω
Ω)

GENERATOR NO-LOAD PERFORMANCE
Remove the left fuel tank side cover. (!7-5)
Disconnect the generator lead wire coupler.
Shift the transmission to the neutral position.
Start the engine and run it at 5 000 r/min.

Measure the AC voltage among the lead wires using the multi
circuit tester.
If the voltage is under the specified value, replace the AC generator with a new one.

# Generator no-load performance (when engine is cold):
65 V and more (AC) at 5 000 r/min
$ 09900-25008: Multi circuit tester set
( Tester knob indication: Voltage (~)

8-9

8-10

ELECTRICAL SYSTEM

REGULATOR/RECTIFIER
Remove the regulator/rectifier.

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Measure the voltage between the terminals using the multi circuit tester, as indicated in the table below.
If the voltage is not within the specified value, replace the regulator/rectifier with a new one.
$ 09900-25008: Multi circuit tester set

* Tester knob indication: Diode test (+)

Unit: V

- Tester probe

A
A
B
C
D
E
F

✽
✽
✽
✽
✽

B
✽
✽
✽
✽
✽

+ Tester probe
C
D
E
F
0.5 1.2 0.4 0.7 0.4 0.7 0.4 0.7
✽
✽
✽
✽
✽
✽
✽
0.4 0.7
✽
✽
0.4 0.7
✽
✽
0.4 0.7
✽
✽

✽ More than 1.4 V (tester s battery voltage)

NOTE:
If the tester reads under 1.4 V when the tester probes are not
connected, replace the battery of multi circuit tester.

ELECTRICAL SYSTEM

8-11

STARTER SYSTEM
R/W

Fuse

Ignition
switch

Engine
stop switch

Neutral relay
O
B/G

Y/B

Reverse
indicator
light

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B/Bl

Neutral
indicator
light

Starter relay

Bl Bl/R

B/W

Battery

Starter
motor

Starter
button

Parking brake switch

CDI

Neutral
switch

TROUBLE SHOOTING

Go to Step 2.
Go to Step 3.

YES
NO

Starter motor will not run.
Step 1
1) The transmission is in neutral. Turn on the ignition switch with the engine stop switch in the RUN position.
2) Listen for a click from the starter relay when the starter button is pushed.
Is a click sound heard ?

Step 2
1) Check if the starter motor runs when its terminal is connected to the + battery terminal. (Do not use thin
wire because a large amount of current flows.)
Does the starter motor run ?
YES
NO

Faulty starter relay
Loose or disconnected starter motor lead wire
Faulty starter motor

8-12

ELECTRICAL SYSTEM

Step 3
1) Measure the starter relay voltage at the starter relay connectors (between Y/B + and B/W -) when the
starter button is pushed.
Is the voltage OK ?

Go to Step 4.
Faulty ignition switch
Faulty engine stop switch
Faulty neutral relay
Faulty neutral switch
Faulty starter button
Poor contact of connector
Open circuit in wire harness

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YES

Step 4
1) Check the starter relay. (!8-15)
Is the starter relay OK ?
YES
NO

Poor contact of the starter relay
Faulty starter relay

NOTE:
The starter motor runs when the transmission is in neutral, but does not run when the transmission is in any
position other than neutral, with the parking lever grasp firmly.
2) Check the parking brake switch. (!8-26)
Is the parking brake switch OK ?

Open circuit in wire harness
Poor contact of connector
Faulty parking brake switch

YES

Engine does not turn though the starter motor runs.
Faulty starter clutch. (!3-40)

ELECTRICAL SYSTEM

STARTER MOTOR REMOVAL AND DISASSEMBLY
Remove the starter motor 1.

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Disassembly the starter motor, as shown.

Housing end (outside)
Brush holder
Brush spring
O-ring
Brush terminal set
Starter motor case
Washer set
Armature
Housing end (inside)
O-ring

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 abnormal wear is 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.

8-13

8-14

ELECTRICAL SYSTEM

ARMATURE COIL INSPECTION
Check for continuity between each segment, and 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 (-)

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OIL SEAL
Check the seal lip for damage or leakage. If any damages are
found, replace the starter motor with a new one.

STARTER MOTOR REASSEMBLY AND
REMOUNTING

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

Replace the removed O-rings with new ones to prevent oil leakage and moisture.
Apply SUZUKI SUPER GREASE to the lip of the oil seal.

. 99000-25030: SUZUKI SUPER GREASE A (USA)
99000-25010: SUZUKI SUPER GREASE A (Others)

Apply a small quantity of SUZUKI MOLY PASTE to the armature shaft.
/ 99000-25140: SUZUKI MOLY PASTE

ELECTRICAL SYSTEM

Align the match marks on the starter motor case with the
match mark on the housing end.
Apply a small quantity of THREAD LOCK to the starter motor
housing bolts and tighten it securely.
0 99000-32050: THREAD LOCK 1342

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Apply SUZUKI SUPER GREASE to the O-ring.
. 99000-25030: SUZUKI SUPER GREASE A (USA)
99000-25010: SUZUKI SUPER GREASE A (Others)

STARTER RELAY INSPECTION

Remove the left fuel tank side cover. (!7-5)
Disconnect the - battery lead wire from the battery terminal.
(!8-8)
Open the starter relay cover 1.

Disconnect the starter motor lead wire 1 and battery lead
wire 2 from the starter relay.
Remove the starter relay from the frame.
Disconnect the starter relay coupler 3.

8-15

8-16

ELECTRICAL SYSTEM

Apply 12 V to the terminals and check for continuity between the
positive and negative terminals using the multi circuit tester. If
the starter relay clicks and continuity is found, the relay is OK.
$ 09900-25008: Multi circuit tester set
, Tester knob indication: Continuity test (-)
"

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Do not apply a battery voltage to the starter relay for
more than five seconds.
This may overheat and damage the relay coil.
Measure the relay coil resistance between the terminals using
the multi circuit tester. If the resistance is not within the specified
value, replace the starter relay with a new one.
# Starter relay resistance
Standard: 3 6 Ω

$ 09900-25008: Multi circuit tester set

) Tester knob indication: Resistance (Ω
Ω)

NEUTRAL RELAY INSPECTION

Remove the neutral relay.

First check the insulation between A and B terminals with the
tester. Then apply 12 V to terminals as shown and check the
continuity between A and B. If there is no continuity, replace
the neutral relay with a new one.
$ 09900-25008: Multi circuit tester set
, Tester knob indication: Continuity set (-)

PARKING BRAKE SWITCH
(!8-26)

ELECTRICAL SYSTEM

8-17

IGNITION SYSTEM
Engine
stop switch

Ignition
switch

Fuse

Battery

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CDI unit

Ignition
coil

Generator

Parking
brake
switch

Neutral
relay

Spark plug

Neutral
switch

TROUBLESHOOTING

NOTE:
* Check that the transmission is in neutral and the engine stop switch is in the RUN position. Check that
the fuse is not blown and the battery is fully-charged before diagnosing.

No spark or poor spark
Step 1
1) Check the ignition system couplers for poor connections.
Is there connection in the ignition switch couplers ?
YES
NO

Go to Step 2.
Poor connection of couplers

Step 2
1) Measure the battery voltage between input lead wires (O/W and B/W) at the CDI with the ignition switch
in the ON position.
Is the voltage OK ?
YES
NO

Go to Step 3.
Faulty ignition switch
Faulty engine stop switch
Broken wire harness or poor connection of related circuit couplers

8-18

ELECTRICAL SYSTEM

Step 3
1) Measure the ignition coil primary peak voltage. (!8-19)
NOTE:
This inspection method is applicable only with the multi circuit tester and the peak volt adaptor.
Is the peak voltage OK ?
YES
NO

Go to Step 4.
Go to Step 5.

YES
NO

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Step 4
1) Inspect the spark plug. (!2-7)
Are the spark plug OK ?

Poor connection of the spark plug cap
Go to Step 5.
Faulty spark plug

Step 5
1) Inspect the ignition coil. (!8-20)
Are the ignition coil OK ?
YES
NO

Go to Step 6.
Faulty ignition coil

Step 6
1) Measure the pickup coil peak voltage and its resistance. (!8-20 to -21)

NOTE:
The pickup coil peak voltage inspection is applicable only with the multi circuit tester and peak volt adaptor.
Are the peak voltage and its resistance OK ?

YES

Faulty CDI
Open circuit in wiring harness.
Poor connection of ignition couplers
Faulty pickup coil

ELECTRICAL SYSTEM

8-19

INSPECTION
IGNITION COIL PRIMARY PEAK VOLTAGE
Disconnect the spark plug cap.
Connect a new spark plug to the spark plug cap and ground it
to the cylinder head.
NOTE:
Make sure that the spark plug cap and spark plug are connected
properly and the battery is fully-charged.

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Measure the ignition coil primary peak volt using the multi circuit
tester in the following procedure:

Connect the multi circuit tester with the peak voltage adaptor
as follows.
+ Probe: Black/White lead wire
- Probe: White/Blue lead wire

NOTE:
Do not disconnect the ignition coil primary wire.
$ 09900-25008: Multi circuit tester set
"

Peak volt adaptor

When using the multi circuit tester and peak volt adaptor, refer to the appropriate instruction manual.

Shift the transmission to the neutral position and turn the ignition switch to the ON position.
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.
# Ignition coil primary peak voltage: 120 V and more
( Tester knob indication: Voltage (&)
1

While testing, do not touch the tester probes and
spark plug to prevent receiving an electric shock.
If the voltage is lower than the standard values, inspect the ignition coil. (!8-20)

Ignition
coil

CDI
unit

Battery

New spark plug

8-20

ELECTRICAL SYSTEM

IGNITION COIL RESISTANCE
Disconnect the ignition coil lead wires and spark plug cap.
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.

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# Ignition coil resistance
Primary
: 0.05 1.0 Ω (+ Terminal - Terminal)
Secondary : 10.5 19.0 kΩ
Ω
(Spark plug cap + Terminal)
$ 09900-25008: Multi circuit tester set

) Tester knob indication: Resistance (Ω
Ω)

PICKUP COIL PEAK VOLTAGE

NOTE:
Make sure all of the couplers are connected properly.

Remove the seat. (!7-5)
Disconnect the CDI unit coupler 1.

Measure the pickup coil peak voltage in the following procedure:

Connect the multi circuit tester with the peak volt adaptor as
follows.

Generator
coupler

Pickup coil: + Probe...Green/White lead wire
- Probe...Black/Yellow lead wire
$ 09900-25008: Multi circuit tester set
"

B/Y

G/W

Generator
Pickup coil

When using the multi circuit tester and peak volt adaptor, refer to the appropriate instruction manual.

Wiring
harness
coupler
Peak volt adaptor

ELECTRICAL SYSTEM

Shift the transmission to the neutral position, turn the ignition
switch to the ON position.
Press the starter button and allow the engine to turn for a few
seconds, and then measure the pickup coil peak voltage.
Repeat the above procedure a few times and measure the
highest pickup coil peak voltage.
# Pickup coil peak voltage: 4.0 V and more
( Tester knob indication: Voltage (&)

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

If the peak voltage measured on the CDI unit coupler is lower
than the standard value, measure the peak voltage on the generator coupler as follows:

Remove the left fuel tank side cover. (!7-5)
Disconnect the generator coupler and connect the multi circuit
tester with the peak volt adaptor as follows.
Pickup coil: + Probe...Green/White lead wire
- Probe...Blue/Yellow lead wire

Measure the pickup coil peak voltage in the same manner as on
the CDI unit coupler.
# Pickup coil peak voltage: 4.0 V and more

G/W

( Tester knob indication: Voltage (&)

If the peak voltage on the generator coupler is within the 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 generator with a new one.
PICKUP COIL RESISTANCE
Remove the left fuel tank side cover. (!7-5)
Disconnect the generator coupler.

Measure the resistance between the lead wires using the multi
circuit tester. If the resistance is not within the specified value,
stator coil must be replaced.
# Pickup coil resistance: 80

155 Ω (B/Y

$ 09900-25008: Multi circuit tester set
( Tester knob indication: Resistance (Ω
Ω)

Peak volt adaptor

B/Y

G/W)

Generator

Pickup coil

8-21

8-22

ELECTRICAL SYSTEM

LAMPS
HEADLIGHT

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Head light: 12 V 40/40 W

7.8 N•m (0.78 kgf-m, 5.6 lb-ft)

E-28 ONLY

1.8 N•m
(0.18 kgf-m, 1.3 lb-ft)

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.

HEADLIGHT BULB REPLACEMENT
Disconnect the coupler.
Remove the bulb.
Install new bulb in the reverse order of removal.

HEADLIGHT BEAM ADJUSTMENT
Adjust the headlight vertical beam by loosening the screw 1.

ELECTRICAL SYSTEM

8-23

BRAKE LIGHT/TAILLIGHT

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Brake light/taillight: 12 V 21/5 W

E-28 Only

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.

BULB REPLACEMENT
Disconnect the socket.
Remove the bulb.
Install new bulb in the reverse order of removal.

8-24

ELECTRICAL SYSTEM

INSPECTION
RE

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

INDICATOR LIGHT

Bl/R

NU: Neutral indicator light

O/Bl

Bl/B

WIRE COLOR
Bl/B : Blue with Black tracer
Bl/R : Blue with Red tracer
O/Bl : Orange with Blue tracer

O/Bl

ITEM

Steering
stem
head cover

Bl/R

RE: Reverse indicator light

INDICATOR LIGHT POSITION

Steering
stem head
cover
Neutral indicator light
(Bl/B & O/Bl)

Reverse indicator light
(Bl/R & O/Bl)

WIRE COLOR
Bl/B : Blue with Black tracer
Bl/R : Blue with Red tracer
O/Bl: Orange with Blue tracer

ELECTRICAL SYSTEM

DIODE

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Remove the fuel tank left side cover. (!7-5)
Remove the neutral switch diode 1.

Measure the voltage between the terminals using the multi circuit tester as indicated in the table below.
" 09900-25008: Multi circuit tester set

# Tester knob indication: Diode test ($)

- Tester
probe

Unit: V

A
B
C

+ Tester probe
B
✽

0.4 0.6
✽

C
✽
0.4 0 .6

✽

✽ More than 1.4 V (tester s battery voltage)

NOTE:
If the tester reads under 1.4 V when the tester probes are not
connected, replace the battery of multi circuit tester.

8-25

8-26

ELECTRICAL SYSTEM

SWITCHES
Measure each switch for continuity using the multi circuit tester. If any abnormality is found, replace the
respective switch assemblies with a new one.
" 09900-25008: Multi circuit tester set

NEUTRAL SWITCH

IGNITION SWITCH
Color

Position

Color

Position

B/W

Neutral
Reverse

STARTER BUTTON
Color

Position

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Others

PARKING BRAKE SWITCH

O/W

Y/G

Color

Position

B/W

B/Bl

OFF

DIMMER SWITCH

BRAKE LIGHT LEVER SWITCH (R)
Color

Position
ON

OFF

Terminal

ON
OFF

Position

ON
OFF

Color

Position

Color

O/W

WIRE COLOR

BRAKE LIGHT PEDAL SWITCH
Position

Color

ENGINE STOP SWITCH

BRAKE LIGHT LEVER SWITCH (L)
Color

Position

W/B

B
Bl
G
Gr
O
R
Y

: Black
: Blue
: Green
: Gray
: Orange
: Red
: Yellow

B/Bl
B/W
O/W
O/G
W/B
Y/G

: Black with Blue tracer
: Black with White tracer
: Orange with White tracer
: Orange with Green tracer
: White with Black tracer
: Yellow with Green tracer

ELECTRICAL SYSTEM

BATTERY
SPECIFICATIONS
Type designation
Capacity
Anode plates
Separator (fiberglass plate)
Cathode plates
Upper cover breather

e
f
g
h

Stopper
Filter
Terminal
Safety valve

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

a
b
c
d

YTX9-BS
12 V, 28.8 kC (8 Ah)/10 HR

INITIAL CHARGING

FILLING ELECTROLYTE
Remove the aluminum tape 1 sealing the battery electrolyte
filler holes 2.

Remove the caps 3.

NOTE:
* After filling the electrolyte completely, use the removed caps
3 as the sealing caps of the battery electrolyte filler holes.
* Do not remove or pierce the sealed portions 4 of the electrolyte container.

Insert the nozzles of the electrolyte container 5 into the battery electrolyte filler holes, holding the container firmly so that
it does not fall. Take a precaution not to allow any of the fluid
to spill.

8-27

8-28

ELECTRICAL SYSTEM

Make sure that air bubbles 6 are coming up into each electrolyte container, and leave it in this position for more than 20
minutes.

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

NOTE:
If no air bubbles are coming up from a filler port, tap the bottom
of the electrolyte container two or three times.
Never remove the container from the battery.

After confirming that the electrolyte has entered the battery
completely, remove the electrolyte container from the battery.
Wait for more than 20 minutes.

Insert the caps 3 into the filler holes, pressing in firmly so that
the caps do not protrude above the upper surface of the battery top cover.
"

* Never use anything except the specified battery.
* Once install the caps to the battery; do not remove
the caps.
* Do not tap the caps with a hammer when installing
them.

CORRECT

For initial charging, use a charger specially designed for MF
batteries.

INCORRECT

ELECTRICAL SYSTEM

8-29

"
* For charging the battery, make sure to use a charger
specially designed for MF batteries. Otherwise, the
battery may be overcharged resulting in shortned
service life.
* Do not remove the caps while charging.
* Position the battery with the cap facing upward while
charging.

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

SERVICING

Visually inspect the surface of the battery. If any signs of cracking or electrolyte leakage 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.

RECHARGING OPERATION

Measure the battery voltage with the multi circuit tester. If the
voltage reading is less than 12 V (DC), recharge the battery
with a battery charger.

(V)
14

(at 0

40 ßC, 32 — 104 ßF)

13
12

$ 09900-25008: Multi circuit tester set

* When recharging the battery, remove the battery
from the vehicle.
* Do not remove the caps while recharging.

100 75 50 25
0 (%)
Battery charged condition

Recharging time: 0.9 A for 5 to 10 hours or 4 A for 1 hour.
"

Be careful not to permit the charging current to
exceed 4 A at any time.

After recharging, wait at least 30 minutes and then measure
the battery voltage with the multi circuit tester. If the battery
voltage is less than 12.5 V, recharge the battery again. If the
battery voltage is still less than 12.5 V after recharging twice,
replace the battery with a new one.
When a battery is left unused for a long time, its voltage needs
to be regularly measured. When the vehicle is not used for more
than one month (especially during the winter season), measure
the battery voltage at least once a month.

Charging period

(V)
18
17
16
15
14
13
12

Stop charging

20 30
Time

50 60
(Minutes)

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

SERVICING INFORMATION

9-1

SERVICING INFORMATION

CONTENTS

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

TROUBLESHOOTING .................................................................................. 9- 2
ENGINE .................................................................................................. 9- 2
DRIVE TRAIN ........................................................................................ 9- 5
CARBURETOR ...................................................................................... 9- 5
CHASSIS ............................................................................................... 9- 6
BRAKES ................................................................................................ 9- 7
ELECTRICAL ......................................................................................... 9- 8
BATTERY .............................................................................................. 9- 9
WIRING DIAGRAM ....................................................................................... 9-10
WIRING HARNESS, CABLE, AND HOSE ROUTING .................................. 9-11
WIRING HARNESS ROUTING .............................................................. 9-11
CABLE ROUTING ................................................................................. 9-13
CARBURETOR HOSE ROUTING ......................................................... 9-16
FRONT BRAKE HOSE ROUTING ........................................................ 9-17
REAR BRAKE BREATHER HOSE ROUTING ...................................... 9-18
FUEL HOSE ROUTING ......................................................................... 9-19
REAR BRAKE CAM LEVER SET-UP .......................................................... 9-20
STEERING HEAD COVER SET-UP ............................................................. 9-21
TAILLIGHT SET-UP ...................................................................................... 9-22
SPECIAL TOOLS .......................................................................................... 9-23
TIGHTENING TORQUE ................................................................................ 9-26
ENGINE .................................................................................................. 9-26
DRIVE TRAIN ........................................................................................ 9-27
CHASSIS ............................................................................................... 9-27
TIGHTENING TORQUE CHART ........................................................... 9-28
SERVICE DATA ............................................................................................ 9-29

9-2

SERVICING INFORMATION

TROUBLESHOOTING
ENGINE
Complaint

Replace.
Replace.
Repair or replace.
Tighten.
See electrical section.
Adjust.
Adjust.
Clean or replace.
Clean and dry or replace.
Replace.
Replace.
Replace.
Replace.

No fuel reaching the carburetor
1. Clogged fuel tank vent hose.
2. Clogged or defective fuel valve.
3. Defective carburetor needle valve.
4. Clogged fuel hose.
5. Clogged fuel filter.
1. Fouled spark plug.
2. Defective generator.
3. Defective CDI unit.
4. Clogged or defective fuel valve.
5. Clogged carburetor jet.
6. Valve clearance out of adjustment.

Clean or replace.
Clean or replace.
Replace.
Clean or replace.
Clean or replace.
Clean or replace.
Replace.
Replace.
Clean or replace.
Clean.
Adjust.

Excessive valve chatter
1. Excessive valve clearance.
2. Weak or broken valve spring.
3. Worn rocker arm and rocker arm shaft.

Adjust.
Replace.
Replace.

Noise seems to come from the piston
1. Worn piston.
2. Worn cylinder.
3. Carbon build-up in combustion chamber.
4. Worn piston pin or piston pin bore.
5. Worn piston ring or ring groove.

Replace.
Replace.
Clean.
Replace.
Replace.

Engine is noisy.

Remedy

Spark plug not sparking
1. Fouled spark plug.
2. Wet spark plug.
3. Defective ignition coil.
4. Open or short in high-tension cord.
5. Defective generator.
6. Defective CDI unit.

Engine stalls easily.

Symptom and possible causes
Compression too low
1. Worn cylinder.
2. Worn piston ring.
3. Worn valve guide or improper valve seating.
4. Loose spark plug.
5. Slow cranking starter motor.
6. Mistimed valves.
7. Valve clearance out of adjustment.

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Engine will not start
or is hard to start.

Noise seems to come from the cam chain
1. Stretched cam chain.
2. Worn cam chain sprocket.
3. Improperly working cam chain tension adjuster.
Noise seems to come from the clutch
1. Worn splines of crankshaft or inner race.
2. Worn splines of countershaft or hub.
3. Worn teeth of clutch plates.
4. Distorted clutch plates, driven and drive.
5. Clutch dampers weakened.

Replace cam chain and
sprockets.
Replace cam chain and
sprockets.
Repair or replace.
Replace.
Replace.
Replace.
Replace.
Replace.

SERVICING INFORMATION

Symptom and possible causes
Noise seems to come from the crankshaft
1. Worn or burnt bearing.
2. Big-end bearing worn or burnt.
3. Excessive thrust clearance.

Remedy
Replace.
Replace.
Replace.

Noise seems to come from transmission
1. Gears worn or rubbing.
2. Badly worn splines.
3. Primary gears worn or rubbing.
4. Badly worn bearings.
5. Worn bushing.

Replace.
Replace.
Replace.
Replace.
Replace.

Noise seems to come from transfer
1. Worn down gears or shafts.
2. Damage to bearings/bushing.

Replace.
Replace.

Noise seems to come from secondary bevel gear and
rear drive bevel gear
1. Drive and driven bevel gears damaged or worn.
2. Excessive backlash.
3. Improper tooth contact.
4. Damage to bearing.
5. Gears worn or rubbing.
6. Badly worn splines.
7. Secondary bevel gear thrust clearance too large.
8. Rear drive bevel gear thrust clearance too large.
1. Clutch control out of adjustment or loss of play.
2. Weakened clutch springs.
3. Worn clutch shoes.
4. Worn or distorted pressure plate.
5. Distorted clutch plates, driven and drive.

Replace.
Adjust.
Adjust.
Replace.
Replace.
Replace
Adjust or replace.
Adjust or replace.
Adjust.
Replace.
Replace.
Replace.
Replace.

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Complaint
Engine is noisy.

Slipping clutch.

1.
2.
3.
4.
1.
2.
3.
4.
5.
1.
2.
3.
4.

Clutch control out of adjustment or too much play.
Some clutch springs weakened while others are not.
Distorted pressure plate or clutch plates.
Worn or damage clutch release mechanism.
Broken gearshift cam.
Distorted gearshift forks.
Worn gearshift shaft.
Worn or damage clutch release mechanism.
Improperly adjusted reverse cable.
Broken reverse shift cam.
Shift shafts are rubbing or sticky.
Distorted or worn gearshift forks.
Broken or damaged gearshift lever return spring.

Adjust.
Replace.
Replace.
Adjust or replace.
Replace.
Replace.
Replace.
Adjust or replace.
Adjust.
Replace.
Repair
Replace.
Replace.

1.
2.
3.
4.
1.
2.
3.
4.
5.

Worn shifting gears on driveshaft or countershaft.
Distorted or worn gearshift forks.
Weakened cam stopper spring on gearshift cam.
Worn gearshift lever stopper pin.
Broken or worn sliding dog.
Broken or worn gearshift fork.
Worn gearshift cam.
Weakened cam stopper spring.
Worn gearshift fork shaft.

Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.

Dragging clutch.

Transmission will not
shift.

Transmission will not
shift back.

Transmission jumps
out of gear.

Transfer will not shift
or shift back.

9-3

9-4

SERVICING INFORMATION

Complaint
Engine idles poorly.

Dirty or heavy
exhaust smoke.

9.
1.

2.
3.
4.
5.
6.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

P
Engine overheats.

Adjust.
Replace.
Replace.
Replace.
Replace.
Replace.
Adjust or replace.
Replace.
Adjust.
Clean.
Replace.
Adjust.
Replace.
Adjust.
Replace.
Adjust.
Replace.
Adjust.
Clean.
Clean and prime.

Worn piston rings or cylinder.
Worn valve guides.
Cylinder wall scored or scuffed.
Worn valve stems.
Defective stem seals.
Loss of valve clearance.
Weakened valve springs.
Valve timing out of adjustment.
Worn piston ring or cylinder.
Poor seating of valves.
Fouled spark plug.
Worn rocker arms or shafts.
Spark plug gap incorrect.
Clogged jets in carburetor.
Float-chamber fuel level out of adjustment.
Clogged air cleaner element.
Too much engine oil.
Sucking air around intake pipe.

Replace.
Check with inspection window,
drain out excess oil.
Replace.
Replace.
Replace.
Replace.
Replace.
Adjust.
Replace.
Adjust.
Replace.
Repair.
Clean or replace.
Replace.
Adjust or replace.
Clean.
Adjust.
Clean.
Drain out excess oil.
Retighten or replace.

Heavy carbon deposit on piston crown.
Not enough oil in the engine.
Defective oil pump or clogged oil circuit.
Fuel level too low in float chamber.
Air leak from intake pipe.
Use of incorrect engine oil.

Clean.
Add oil.
Replace or clean.
Adjust.
Retighten or replace.
Change.

Engine lacks power.

Remedy

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Engine runs poorly in 1.
high speed range.
2.
3.
4.
5.
6.
7.
8.

Symptom and possible causes
Valve clearance out of adjustment.
Poor seating of valves.
Defective valve guides.
Worn rocker arm or arm shaft.
Defective generator.
Defective CDI unit.
Spark plug gap too wide.
Defective ignition coil resulting in weak sparking.
Float-chamber fuel level out of adjustment in carburetor.
Clogged jets.
Defective fuel valve.
Improperly set pilot screw.
Valve springs wakened.
Valve timing out of adjustment.
Worn cams or rocker arms.
Spark plug gap too narrow.
Defective ignition coil.
Float-chamber fuel level tool low.
Clogged air cleaner element.
Clogged fuel pipe, resulting in inadequate fuel supply to
carburetor.
Defective fuel valve.
Too much engine oil in the engine.

1.
2.
3.
4.
5.
6.

SERVICING INFORMATION

9-5

DRIVE TRAIN
Complaint
Power will not transmit from the engine to
the rear wheel.

Symptom and possible causes
1.
2.
3.
4.
5.
6.

Broken drive and driven bevel gear teeth.
Broken propeller shaft serration.
Worn or broken rear axle serration.
Worn or damaged coupling joint serration.
Broken or damaged rear drive and driven bevel gears.
Worn or damaged universal joint.

Remedy
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.

CARBURETOR
Symptom and possible causes
Clogged starter jet.
Clogged starter jet passage.
Air leaking from joint between starter body and carburetor.
Improperly working starter (enricher) plunger.
Clogged or loose pilot jet.
Clogged pilot jet passage.
Clogged pilot outlet port.
Clogged bypass port.
Starter (enricher) plunger not fully closed.
Improperly set pilot screw.
Incorrect float height.
Clogged main jet.
Clogged main air jet.
Clogged needle jet.
Improperly working throttle valve.
Clogged fuel filter.
Incorrect float height.
Starter (enricher) plunger not fully closed.

Remedy

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Complaint
Starting difficulty.

Idling or low-speed
trouble.

4.
1.
2.
3.
4.
5.
6.
7.
1.
2.
3.
4.
5.
6.
7.

Medium-or high
speed trouble.

1.
2.
3.

Overflow and fuel
level fluctuations.

1.
2.
3.
4.

Worn or damaged needle valve.
Broken needle valve spring.
Improperly working float.
Foreign matter on the needle valve.

5. Incorrect float chamber fuel level.

Clean.
Clean.
Tighten, adjust or replace gasket.
Adjust.
Clean or tighten.
Clean.
Clean.
Clean.
Adjust.
Adjust.
Adjust.
Clean.
Clean.
Clean.
Adjust.
Clean or replace.
Adjust.
Adjust.

Replace.
Replace.
Adjust or replace.
Clean or replace with needle
valve seat.
Adjust float height.

9-6

SERVICING INFORMATION

CHASSIS
Complaint

Steering wobbles.

Steering pulls to one
side.

Shocks felt in the
steering.
Tires rapidly or
unevenly wear.
Steering too noisy.

Adjust.
Improper front wheel alignment.
Lubricate.
Insufficiently lubricated.
Adjust.
Low air pressure in front tires.
Replace.
Tie rod ends tending to seize.
Repair or replace.
Linkage connections tending to seize.
Regulate.
Unequally inflated tires.
Tighten.
Loose front wheel hub nuts.
Replace.
Damaged or worn front wheel hub bearings.
Replace or tighten.
Worn or loose tie rod ends.
Replace.
Defective or incorrect front tires.
Damaged or worn wishbone arms and related bush- Replace.
ings.
Replace.
Distorted front wheels.
Tighten.
Loose chassis nuts and bolts.
Regulate.
Unequally inflated tires.
Adjust.
Improper front wheel alignment.
Replace.
Worn front wheel hub bearings.
Repair or replace.
Distorted frame or wishbone.
Replace.
Defective shock absorber.
Regulate.
High tire pressure.
Replace.
Worn steering linkage connections.
Tighten.
Loose suspension system bolts.
Worn or loose front wheel hub bearings.
Replace.
Improper front wheel alignment.
Adjust.
Tighten.
Loose nuts and bolts.
Replace.
Damaged or worn front wheel hub bearings.
Lubricate.
Insufficiently lubricated.
Weakened spring.
Replace.
Shock absorber leaks oil.
Replace.

7.
8.
1.
2.
3.
4.
5.
1.
2.
3.
1.
2.
1.
2.
3.
1.
2.

Suspension too soft.

1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
6.

Remedy

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Handling is too heavy
or stiff.

Symptom and possible causes

1. Worn upper or lower wishbone arms and related bush- Tighten.
ings.
2. Bent shock absorber rod.
Replace.
Tighten.
1. Loose suspension system bolts.
Replace.
2. Worn wishbone arms and related bushings.
Replace.
3. Worn swingarm bushings.

Suspension too stiff.

Suspension too
noisy.

Rear wheels wobble.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Distorted rear wheel rims.
Damage or worn rear brake panel bearings.
Defective or incorrect rear tires.
Loose rear wheel hub nuts.
Distorted rear axle.
Loosen rear axle housing mounting bolts.
Improper rear brake adjustment.
Damaged or worn rear swingarm and related bushings.
Rear shock absorber leaks oil.
Loose rear swingarm nut.

Replace.
Replace.
Replace.
Tighten.
Replace.
Tighten.
Adjust.
Replace.
Replace.
Tighten.

SERVICING INFORMATION

9-7

BRAKES
Complaint

Symptom and possible causes

Remedy

1.
2.
3.
4.
1.
2.

Insufficient brake fluid.
Air in brake fluid circuit.
Worn pads.
Worn disc.
Worn shoe linings.
Too much play on brake pedal or brake lever.

Refill to level mark.
Bleed air out.
Replace.
Replace.
Replace.
Adjust.

1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
6.

Leakage of brake fluid from hydraulic system.
Worn pads, worn lining.
Oil adhesion on engaging surface of pads.
Worn disc or bake drum.
Air in hydraulic system.
Carbon adhesion on pad surface.
Carbon adhesion on lining surface.
Titled pad.
Loose front wheel axle or rear wheel axle.
Worn brake pads and linings.
Foreign material in brake fluid.
Clogged return port of master cylinder.

Excessive brake lever
stroke.

7.
8.
1.
2.

Wrongly fixed spring.
Caliper binding on caliper axles.
Air in hydraulic system.
Insufficient brake fluid.

Brake fluid leakage.

3. Improper quality of brake fluid.
1. Insufficient tightening of connection joints.

Repair or replace.
Replace.
Clean disc and pads.
Replace.
Bleed.
Repair surface with emery
paper.
Modify pad fitting or replace.
Tighten to specified torque.
Replace.
Replace brake fluid.
Disassemble and clean master
cylinder.
Set correctly.
Clean and lubricate.
Bleed.
Replenish fluid to specified
level and bleed air.
Replace with correct fluid.
Tighten to specified torque and
add brake fluid.
Replace.
Replace piston and/or cup.

Poor braking.
(FRONT)

Poor braking.
(REAR)

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Insufficient brake
power.

Brake squeaks.

2. Cracked hose.
3. Worn piston and/or cup.

9-8

SERVICING INFORMATION

ELECTRICAL
Complaint

Spark plug is wet or
quickly becomes
fouled with carbon.

Spark plug quickly
becomes fouled with
oil or carbon.

Spark plug electrodes
overheat or burn.

Generator does not
charge.

Defective ignition coil.
Defective spark plug.
Defective generator.
Defective CDI unit.
Defective pickup coil.
Excessively rich air/fuel mixture.
Excessively high idling speed.
Incorrect gasoline.
Dirty air cleaner element.
Incorrect spark plug (cold type).

1.
2.
3.
4.
5.

Worn piston ring.
Worn piston.
Worn cylinder.
Excessive valve-stem-to-valve-guide clearance.
Worn valve stem oil seal.

Replace.
Replace.
Replace.
Replace.
Replace.
Adjust carburetor.
Adjust carburetor.
Change.
Clean or replace.
Change to standard spark
plug.
Replace.
Replace.
Replace.
Replace.
Replace.

1. Incorrect spark plug.

2.
3.
4.
1.

2.
3.
1.
2.
3.

Change to cold type spark
plug.
Turn-up.
Overheated engine.
Tighten.
Loose spark plug.
Adjust carburetor.
Excessively lean air/fuel mixture.
Open or short in lead wires, or loose lead connections. Repair, replace or connect
properly.
Replace.
Shorted, grounded or open generator coil.
Replace.
Shorted or punctured regulator/rectifier.
Lead wires tend to get shorted, open-circuited, or Repair or tighten.
loosely connected at terminal.
Grounded or open-circuited stator coils or generator.
Replace.
Defective regulator/rectifier.
Replace.

Generator charges
but charging rate is
below specification.

1.
2.
3.
4.
5.
1.
2.
3.
4.
5.

Remedy

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

No sparking or poor
sparking.

Symptom and possible causes

1. Internal short-circuit in the battery.
Replace battery.
2. Damaged or defective regulator/rectifier.
Replace.
1. Lead wire insulation frayed due to vibration, resulting in Repair or replace.
intermittent shorting.
2. Internally shorted generator.
Replace.
3. Defective regulator/rectifier.
Replace.

Generator overcharges.
Unstable charging.

Starter button does
not work.

Recharge or replace.
1. Run down battery.
Replace.
2. Defective switch contact.
3. Brushes do not seat properly on the commutator in the Repair or replace.
starter motor.
Replace.
4. Defective starter relay.
Replace.
5. Defective neutral relay.
Replace.
6. Defective emergency switch. (E-17)
Replace.
7. Defective engine stop switch.
Replace.
8. Defective neutral switch.
Replace.
9. Defective parking brake switch.
Connect, tighten or repair.
10. Wiring connections loose or disconnected.

SERVICING INFORMATION

9-9

BATTERY
Complaint

Remedy

Replace.
1. Cracked battery case.
2. Battery has been left in a run-down condition for a long Replace.
time.
Check the generator, and regu1. Incorrect charging method.
lator/rectifier circuit connections, and make necessary
adjustments to obtain specified
charging operation.
2. Battery cell plates have lost much of their active mate- Replace the battery and correct the charging system.
rial as a result of overcharging.
Replace.
3. Internally shorted battery.
Replace.
4. Old battery.
1. Improperly connected battery leads.
Replace the battery and be
sure to connect it properly.
(i.e., - to + and + to -)

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Sulfation or spots on
surfaces of cell
plates.
Battery runs down
quickly.

Symptom and possible causes

Reversed battery
polarity.

1. Dirty container top and sides.
2. Old battery.
1. Incorrect charging rate.
(When not in use, the battery should be checked at
least once a month and properly charged if necessary,
to avoid sulfation.)
2. The battery was left unused in a cold climate for too
long.

Battery discharged
too rapidly.
Battery sulfation.

Clean.
Replace.
Replace.

Replace the battery if badly
sulfated.

LIGHT
ON
OFF

IGNITION
SWITCH

BRAKE LIGHT
SWITCH (L)

OFF
ON

O
W/B

Gr
O
B

B/Br

B/W

B/Bl

PARKING
BRAKE
SWITCH

NEUTRAL
SWITCH

Bl/B

B/Bl

Bl/B

NEUTRAL
DIODE

O
W

Y/B

B/Bl

NEUTRAL
RELAY

B/G

Y/G

B/G

O/W
B/R

Y
B/Y

Bl/R

B B/O

B/O

BRAKE LIGHT
SWITCH (R)

OFF
ON

W
B/Bl

OFF
ON

Bl/R

B/W

REGULATOR/
RECTIFIER

B/R

Y/B

CDI UNIT

GENERATOR

STARTER
MOTOR

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86
W

B/Bl

B/W

B/Y

B/Y
B/W
W

IGNITION
COIL

O/Bl

O W/B

Bl/B

ON
OFF

PUSH

BRAKE LIGHT SWITCH

B/W

STARTER
BUTTON

W/Bl

RUN
OFF

B/W

ENGINE STOP
SWITCH

B/Y

HEADLIGHT

HI
LO

STARTER
RELAY

1 FUSE : 20A

BATTERY

DIMMER
SWITCH

B/W

G/Y
G/W
G/W

Bl
O
Bl/R

Bl/R

NU : NEUTRAL INDICATOR LIGHT
RE : REVERSE INDICATOR LIGHT

B/W

W/B

B/O

15A

G/W

B/W

B
B

Bl/R

INDICATOR LIGHT

B/O
B

W/Bl

FUSE BOX

Bl/B

B/Y

W/B
W/B

B : Black
Bl : Blue
Gr : Gray
O : Orange
R : Red
W : White
Y : Yellow
B/Bl : Black with Blue tracer
B/Br : Black with Brown tracer
B/W : Black with White tracer
B/Y : Black with Yellow tracer
B/R : Black with Red tracer
B/G : Black with Green tracer
B/O : Black with Orange tracer
Bl/B : Blue with Black tracer
Bl/R : Blue with Red tracer
G/W : Green with White tracer
O/Bl : Orange with Blue tracer
O/W : Orange with White tracer
W/B : White with Black tracer
W/Bl: White with Blue tracer
Y/B : Yellow with Black tracer
Y/G : Yellow with Green tracer

WIRE COLORS

B/W
B/W

TAIL LIGHT
Gr
Gr

9-10
SERVICING INFORMATION

WIRING DIAGRAM

SERVICING INFORMATION

WIRING HARNESS, CABLE, AND HOSE ROUTING
WIRING HARNESS ROUTING

Brake light/Taillight

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Wiring harness
Handlebar switch
Ignition swich
Reverse cable

Wiring harness
Battery

Clamp

Ignition coil

Parking brake
Pilot lamp
Left brake switch
Clamp

Set the generator coupler inside of the frame.

Clamp

Wiring harness

EC approval label

Wiring harness

Neutral relay

(E-28)

Regulator/rectifier

IECS label (E-28)

Starter relay

Starter motor
Generator
Battery

Cut the tip of the clamp
after clamping
the several lead wire.

Clamp

Clamp
Starter motor
Generator
Battery

Starter motor
Clamp

Cut the tip of
the clamp after
clamping the pedal
switch lead wire.

Neutral switch
Brake pedal switch
Clamp

Brake light pedal switch

9-11

9-12

SERVICING INFORMATION

Ignition switch
Handlebar switch (L)
Parking brake switch
Brake lever switch
Starter cable

Front brake switch
Clamp

Forward

Set the coupler inside.
Clamp

Pass the lead wire on the upper bracket.
Neutral switch
lead wire
Rear brake lamp
switch harness

30ß

VIEW A

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

10ß

Clamp

Battery

Carburetor
drain hose

Starter motor
lead wire

VIEW B

Generator
lead wire

Grommet

Magneto cover

Neutral
switch
lead wire

Clamp

7 NÆm (0.7 kgf-m, 5.0 lb-ft)

Starter
motor
lead wire

Clamp

6 NÆm
0.6 kgf-m
4.5 lb-ft

(

Starter
motor
VIEW C

Starter motor

)

SERVICING INFORMATION

9-13

CABLE ROUTING
Throttle cable
Parking brake cable

Throttle cable
Reverse cable

Clamp
Brake hose

DETAIL E
E

Reverse cable

Starter cable

Cable guide
Parking brake cable

FRONT

Starter cablle

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Pass the parking
brake cable
behind the brake
hose.

Pass the throttle cable
in front of the parking
brake cable.

Pass the reverse cable
in front of the brake pipe.

Clamp

Brake cable adjuster
Brake cable pin
Make sure that
the small-pitch
portion of the
cable spring
DETAIL A
faces to
the pin.
Rear brake cable spring
FRONT
Pass the throttle cable between
the brake hose and handlebars.
Pass the parking and throttle
cables under the frame.

Clamp

Parking brake cable

Throttle cable

Clamp

Rear brake
cable

Pass the parking
brake cable under
the rear brake cable.
Rear brake cable
Pass the parking
brake cable
inside of the
rear brake cable.

Pass the parking brake cable
through the frame bracket.

Set the pin inside.

Fix the rubber of the parking
brake cable with the cable guide.
Pass the parking brake cable
outside of the frame.
OUTSIDE
Parking brake cable

DETAIL B

Pass the throttle cable
inside of the frame.
Clamp the parking
Clamp
cable with the throttle cable.
Parking brake
Rear brake cable
OUTSIDE cable

DETAIL C

FRONT
Brake cable pin
FRONT

Throttle
cable

Pass the parking cable
and throttle cable
under the frame. DETAIL D

SERVICING INFORMATION

Starter cable
Wiring harness
OUTSIDE
Clamp

Clamp the starter cable
with the wiring harness.
Clamp the starter cable
inside of the frame.

FRONT
DETAIL F

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Parking brake cable

Starter cable

Reverse cable

Pass the starter cable
under the frame.

Clamp

Do not give
too much play.

9-14

Reverse cable pin

Set the pin outside

FRONT

OUTSIDE

Reverse cable

DETAIL G

SERVICING INFORMATION

STEERING SHAFT SET-UP
Tighten the rear bolts
after tightening the front ones.

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Clearance

9-15

9-16

SERVICING INFORMATION

CARBURETOR HOSE ROUTING

Right

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Left

45ß

Right

Air vent hose

Carburetor

Left

Carburetor overflow hose

Clamp

Front
brake
pipe

0ß – 5ß

VIEW D

Foward

VIEW C

Mark

Cable guide

VIEW A

Brake hose guide

Front brake pipe

Pass the brake hose
in front of
the throttle cable.

Throttle cable

Front Brake hose

Wiring harness

The white mark
faces front side.

Foward

SECT FF

Punched mark

Clamp firmly.

Pass the brake pipe
behind the reverse cable.

Reverse cable

Mark

Cable guide

Mark

Pass the brake hose
in front of
the wiring harness.

VIEW B

Clamp
the hose
firmly.

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

After the brake hose union
touching to the stopper,
tighten the union bolt.

(LH)

28ß

SECT EE

Clamp firmly.

After the brake hose union
touching to the stopper,
tighten the union bolt.

(RH)

28ß

SERVICING INFORMATION

FRONT BRAKE HOSE ROUTING
9-17

Frame

Inside

Frame

Inside

Clip

VIEW A

Outside

SECT DD

Fuel tank

Rear brake
breather hose
Frame

Inside

Rear brake
anchor panel

Pass through the rear brake breather hose
into the oblong hole of the swingarm plate.

Clamp

Rear brake cable

Pass the rear brake
breather hose outside
of the frame and
parking brake cable.

Side plate

Inside

Clamp

Outside

Parking brake cable
SECT EE

Outside

NOTE:
*Make sure not to twist and deform
the rear brake breather hose.

VIEW H

Clip

Rear brake
breather hose

Insert the rear brake breather hose
to the breather hose union correctly.

Rear swingarm
SECT FF, GG

Rear brake
breather hose

Parking brake cable
Rear brake
breather hose

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Parking brake cable

Rear brake
breather hose

Outside

Rear brake
breather hose
Parking brake cable

Clip

SECT CC

VIEW B

Parking brake cable

Rear brake
breather hose

30 —40 mm
(1.18 —1.57 in)

Pass through the rear brake
breather hose into the hole
of the fuel tank plate.

9-18
SERVICING INFORMATION

REAR BRAKE BREATHER HOSE ROUTING

Fuel tank front cushion

FRAME

Fuel tank breather
hose No. 2

Steering head cover

Fuel hose

Clip

Cushion

Fuel tank

The end of the clip
faces front side.

Clip

VIEW A

Fuel valve

Fuel cock vacuum hose

Connect the curved side of
the fuel hose to the fuel valve.

4.5 NÆ
m
(0.45 kgf-m, 3.25 lb-ft)

Fuel valve

Pass through the breather hose No. 2
between the handlebars and ignition switch.

Cushion

Pass through the breather hose
No. 2 under the harness.

Handlebar
Set the breather hose into
the hole of the stem shaft.

Spacer

Connect the wide diameter side
of the breather hose No. 2.

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Fuel tank breather hose

VIEW B

Fuel hose

Carburetor

Frame

The end of the clip
faces back side.

Ignition switch

Fuel tank breather
hose No. 2

Handlebars

Ignition switch
harness

Steering head cover

Steering stem shaft

SECT C C

Fuel tnak breather hose No. 2
Ignition switch harness

Steering head cover

SERVICING INFORMATION

FUEL HOSE ROUTING
9-19

Brake panel

Spring

Washer

Brake cam shaft

Brake lining indicator plate

Align the tongue on the indicator plate with
the elimination of one tooth of the brake cam shaft.

Align the punched mark on the brake cam lever
with the slit on the brake cam.

Install the brake cam as its slit faces outside.

Brake lining indicator plate

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

9-20
SERVICING INFORMATION

REAR BRAKE CAM LEVER SET-UP

SERVICING INFORMATION

STEERING HEAD COVER SET-UP

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Steering head cover

Clip

Fuel tank breather
hose No. 2

Steering head cover bracket

9-21

9-22

SERVICING INFORMATION

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

TAILLIGHT SET-UP

Rear fender

Taillight

Rear reflector
Side reflector

E-28 ONLY

SERVICING INFORMATION

9-23

SPECIAL TOOLS

09900-06107
Snap ring pliers

09900-06108
Snap ring pliers

09900-09004
Impact driver set

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

09900-00410
09900-06106
Hexagon wrench set Snap ring pliers

09900-20203
Micrometer
(1/100 mm,
50 75 mm)

09900-20205
Micrometer
(1/1000 mm,
0 25 m m)

09900-20508
Cylinder gauge set
(1/100 mm,
40 80 mm)

09900-20602
Dial gauge
(1/1000 mm)

09900-20605
Dial calipers
(1/100 mm,
10 34 mm)

09900-20607
Dial gauge
(1/100 mm)

09900-20701
Magnetic stand

09900-20803
Tickness gauge

09900-20804
Tickness gauge

09900-20805
Tire depth gauge

09900-21304
V-block set
(100 mm)

09900-22302
Plastigauge

09900-22401
Small bore gauge
(10 18 mm)

09900-25008
Multi circuit tester
set

09900-26006
Tachometer

09910-32812
Crankshaft installer

09913-50121
Oil seal remover

09913-70210
Bearing installer set

09900-20101
Vernier calipers

09900-20202
Micrometer
(1/100 mm,
25 50 mm)

SERVICING INFORMATION

09913-85210
Bearing/oil seal
installer

09916-14510
Valve spring compressor

09916-14910
Valve spring compressor attachment

09916-24935
Valve seat cutter
(N-608)

09915-64510
Compression gauge
set
09918-02410 or
09918-03810
09915-74511
(Adaptor)
Oil pressure gauge

09915-74512
Oil pressure gauge
adaptor

09916-10911
Valve lapper set

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

9-24

09916-22480
Solid pilot
(N-140-5.5)

09916-34550
Valve guide reamer
(5.5 mm)

09916-34561
Valve guide reamer
(11.3 mm)

09916-44910
Valve guide
remover/installer

09921-20240
Bearing remover set

09916-34542
Reamer handle

09916-21111
09916-24450
09916-24900
Solid pilot
Valve seat cutter set (N-100-5.52)

09916-84511
Tweezers

09920-13120
Crankcase separator

09920-53730
Clutch sleeve hub
holder

09921-20210
Bearing puller

09921-21820
Bearing locknut
wrench

09921-21910
Bearing holder

09923-74510
Bearing remover

09924-84510
09930-30104
Bearing installer set Sliding shaft

SERVICING INFORMATION

09930-30721
Rotor remover

09930-35010
Rotor remover

09930-31921
Rotor remover

09930-44520
Rotor holder

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

09930-10121
Spark plug wrench
set

09930-73150
Output shaft holder

09950-81910
Remover

NOTE:
When ordering a special tool, please confirm whether it is available or not.

9-25

9-26

SERVICING INFORMATION

TIGHTENING TORQUE
ENGINE
N•m
10
11
23
10
10
10
8
7
18
9
14
11
23
140
100
23
15
160
15
26
23
23
23
11
21
100
100
66
23
6
10

kgf-m
1.0
1.1
2.3
1.0
1.0
1.0
0.8
0.7
1.8
0.9
1.4
1.1
2.3
14.0
1.0
2.3
1.5
16.0
1.5
2.6
2.3
2.3
2.3
1.1
2.1
10.0
10.0
6.6
2.3
0.6
1.0

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

ITEM
Cylinder head cover bolt
Camshaft sprocket bolt
Cylinder head nut (M8)
Cylinder head nut (M6)
Cylinder base nut (M6)
Cam chain tensioner mounting bolt
Cam chain tension adjuster spring holder bolt
Neutral switch bolt
Spark plug
Rocker arm shaft bolt
Valve clearance adjuster locknut
Crankcase bolt
Valve timing inspection plug
Clutch shoe nut
Clutch sleeve hub nut
Clutch adjuster lock nut
Clutch adjuster cap
Generator rotor nut
Generator cover cap
Starter clutch bolt
Exhaust pipe nut
Muffler mounting bolt/nut
Muffler connecting bolt
Spark arrester bolt
Engine oil drain plug
Secondary drive bevel gear nut
Secondary driven bevel gear nut
Engine mounting bolt/nut
Engine mounting bracket bolt
Starter motor lead wire nut
Starter motor mounting bolt

lb-ft
7.0
8.0
16.5
7.0
7.0
7.0
6.0
5.0
13.0
6.5
10.0
8.0
16.5
101.5
72.5
16.5
11.0
115.5
11.0
19.0
16.5
16.5
16.5
8.0
15.0
72.5
72.5
48.0
16.5
4.5
7.0

SERVICING INFORMATION

DRIVE TRAIN

CHASSIS

N•m
26
100
26
26
60
65
65

kgf-m
2.6
10.0
2.6
2.6
6.0
6.5
6.5

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

ITEM
Final gear case cover bolt
Pinion gear bearing locknut
Rear drive gear oil filler plug
Rear drive gear oil drain plug
Rear axle housing set bolt/nut (RH)
Rear axle housing set bolt/nut (LH)
Rear axle housing/final gear case bolt

ITEM

Handlebar clamp bolt
Steering shaft holder bolt
Steering shaft nut
Wishbone arm pivot bolt/nut (upper and lower)
Wheel hub nut (front)
Wheel hub nut (rear)
Wheel set nut (front and rear)
Steering knuckle nut (upper and lower)
Front shock absorber mounting bolt/nut (upper and
lower)
Tie rod end nut
Tie rod lock nut
Front brake air bleeder valve
Front brake caliper mounting bolt
Front brake pipe nut (Upper and lower)
Front brake pad mounting pin
Front brake caliper holder pin
Front brake caliper holder slide pin
Front brake master cylinder mounting bolt
Front brake hose union bolt
Front brake disc bolt
Front brake disc plate mounting bolt
Footrest bolt (M8)
Footrest bolt (M10)
Rear shock absorber mounting bolt/nut (Upper)
Rear shock absorber mounting bolt/nut (Lower)
Swingarm pivot bolt/nut
Rear brake cam lever bolt/nut
Rear brake pedal mounting bolt
Rear brake panel mounting nut

lb-ft
19.0
72.5
19.0
19.0
43.5
47.0
47.0

N•m
23
23
49
65
65
138
50
29

kgf-m
2.3
2.3
4.9
6.5
6.5
13.8
5.0
2.9

lb-ft
16.5
16.5
35.5
47.0
47.0
99.9
36.0
21.0

6.0

43.5

29
29
6.0
26
16
18
18
23
10
23
23
23
26
55
78
60
85
11
11
60

2.9
2.9
0.6
2.6
1.6
1.8
1.8
2.3
1.0
2.3
2.3
2.3
2.6
5.5
7.8
6.0
8.5
1.1
1.0
6.0

21.0
21.0
4.4
19.0
11.6
13.0
13.0
16.5
7.0
16.5
16.5
16.5
19.0
40.0
55.0
43.5
61.5
8.0
8.0
43.5

9-27

9-28

SERVICING INFORMATION

TIGHTENING TORQUE CHART
For other nuts and bolts not listed in the preceding page, refer to this chart:

4
5
6
8
10
12
14
16
18

Conventional bolt

Conventional or 4 marked bolt
N•m
kgf-m
lb-ft
1.5
0.15
1.0
3
0.3
2.0
5.5
0.55
4.0
13
1.3
9.5
29
2.9
21.0
45
4.5
32.5
65
6.5
47.0
105
10.5
76.0
160
16.0
115.5

N•m
2.3
4.5
10
23
50
85
135
210
240

7 marked bolt
kgf-m
0.23
0.45
1.0
2.3
5.0
8.5
13.5
21.0
24.0

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Bolt Diameter
A (mm)

4 marked bolt

lb-ft
1.5
3.0
7.0
16.5
36.0
61.5
97.5
152.0
173.5

7 marked bolt

SERVICING INFORMATION

9-29

SERVICE DATA
VALVE + GUIDE

Unit: mm (in)

ITEM
Valve diam.

IN.
EX.

Tappet clearance (when cold)

IN.

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

EX.

STANDARD
32
(1.3)
28
(1.1)
0.03 0 .08
(0.001 0 .003)
0.08 0 .13
(0.003 0 .005)
0.010 0 .037
(0.0004 0 .0015)
0.030 0 .057
(0.0012 0 .0024)

Valve guide to valve stem
clearance

IN.

EX.

Valve stem deflection
Valve guide I.D.

Valve stem O.D.

IN. & EX.
IN. & EX.
IN.

EX.

Valve stem runout

IN. & EX.

Valve head thickness

IN. & EX.

Valve stem end length
Valve seat width

Valve head radial runout
Valve spring free length

5.500
(0.2165
5.475
(0.2156
5.455
(0.2148

5
0
5
0
5
0

IN. & EX.
IN. & EX.

0.05
(0.002)
0.5
(0.02)
2.5
(0.10)

0.88 1 .08
(0.035 0 .043)

IN. & EX.

Valve spring tension

0.35
(0.014)

.512
.2170)
.490
.2161)
.470
.2154)

IN. & EX.
IN. & EX.

LIMIT

256 2 94 N
(26.1 3 0.0 kgf, 57.5 66 .1 lbs)
at length 36.6 mm (1.44 in)

0.03
(0.001)
43.0
(1.69)

9-30

SERVICING INFORMATION

CAMSHAFT + CYLINDER HEAD

Unit: mm (in)

ITEM
Cam height

STANDARD
33.780 33.820
(1.3299 1.3315)
32.990 33.030
(1.2988 1.3004)
0.036 0.066
(0.0014 0.0026)
22.012 22.025
(0.8666 0.8671)
21.959 21.976
(0.8645 0.8652)

IN.
EX.

Camshaft journal oil clearance
Camshaft journal holder I.D.

Camshaft runout
Rocker arm I.D.

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Camshaft journal O.D.

Rocker arm shaft O.D.

12.000
(0.4724
11.977
(0.4715

IN. & EX.
IN. & EX.

Cylinder head cover distortion

CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure

Piston to cylinder clearance

Piston diam.

Cylinder distortion

Piston ring free end gap

Piston ring end gap

Piston ring to groove clearance

STANDARD

1 400 kPa
(14.0 kgf/cm2, 199 psi)

0.040 0. 050
(0.0016 0. 0020)
66.000 66. 015
(2.5984 2. 5990)
65.955 65. 970
(2.5966 2. 5972)
Measure at 18 mm (0.71 in) from the skirt end.

1st

Approx. 8.7 (0.34)

2nd

Approx. 9.0 (0.35)

1st

0.10 0. 25
(0.004 0. 010)

2nd

0.10 0. 25
(0.004 0. 010)

1st
2nd

Piston ring groove width

1st
2nd
Oil

1.01
(0.0398
1.21
(0.0476
2.01
(0.0791

0.10
(0.004)

12.018
0.4731)
11.995
0.4722)

Cylinder head distortion

Cylinder bore

LIMIT
33.480
(1.3181)
32.690
(1.2870)
0.150
(0.0059)

1. 03
0. 0406)
1. 23
0. 0484)
2. 03
0. 0799)

0.05
(0.002)
0.05
(0.002)
Unit: mm (in)

LIMIT
1 200 kPa
(12.0 kgf/cm2,
171 psi)
0.120
(0.0047)
66.090
(2.6020)
65.880
(2.5937)

0.05
(0.002)
7.0
(0.28)
7.2
(0.28)
0.50
(0.020)
0.5
(0.020)
0.180
(0.007)
0.150
(0.006)

SERVICING INFORMATION

ITEM
Piston ring thickness

1st
2nd

Piston pin bore
Piston pin O.D.

STANDARD
0.97 0.99
(0.038 0.039)
1.17 1.19
(0.046 0.047)
16.002 16.008
(0.6300 0.6302)
15.992 16.000
(0.6296 0.6299)

CONROD + CRANKSHAFT

Conrod big end width

Crank web to web width

LIMIT
16.040
(0.6315)
3.0
(0.12)

0.10 0. 45
(0.004 0.018)
17.95 18 .00
(0.707 0.709)
53.0 – 0.1
(2.087 – 0.004)

1.0
(0.04)

Crankshaft runout

OIL PUMP

ITEM
Oil pressure (at 60 C, 140 F)

CLUTCH

ITEM
Clutch release screw
Drive plate thickness

Drive plate claw width

STANDARD
Above 30 kPa (0.3 kgf/cm2 , 4.3 psi)
Below 70 kPa (0.7 kgf/cm2, 9.9 psi)
at 3 000 r/min.

STANDARD
1/16 1 /8 turn back
2.7 2. 9
(0.106 0.114)
11.9 12 .0
(0.469 0.472)

Driven plate distortion
Clutch spring free length
Clutch wheel I.D.

28.9
(1.14)
116.00 1 16.15
(4.567 4.573)

Clutch shoe
Clutch engagement r/min.
Clutch lock-up r/min.

16.030
(0.6311)
15.980
(0.6291)

STANDARD
16.006 16 .014
(0.6302 0.6305)

Conrod deflection

Conrod big end side clearance

LIMIT

Unit: mm (in)

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

ITEM
Conrod small end I.D.

9-31

1 700 2 100 r/min
3 100 3 700 r/min

0.08
(0.003)

LIMIT

Unit: mm (in)
LIMIT
2.4
(0.094)
11.0
(0.433)
0.10
(0.004)
27.5
(1.08)
116.5
(4.59)
No groove at
any part

9-32

SERVICING INFORMATION

DRIVE TRAIN

Unit: mm (in) Except ratio
STANDARD
3.047 (64/21)
1.133 (17/15)
3.200 (32/10)
3.083 (37/12)
1.933 (29/15)
1.388 (25/18)
1.095 (23/21)
0.913 (21/23)
2.833 (34/12)
0.10 0.30
(0.004 0.012)
4.50 4.6 0
(0.169 0.173)
4.30 4.40
(0.169 0.173)
0 10
(0 0 .393)
0.03 0.15
(0.001 0.006)
0.05 0.30
(0.002 0.012)

Shift fork groove width
Shift fork thickness

Gearshift lever height

Secondary bevel gear
backlash
Rear drive (final) bevel gear
backlash

CARBRETOR
ITEM

Bore size

I.D. No.
Idle r/min

SPECIFICATION

Carburetor type

Float height
Main jet

LIMIT

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

ITEM
Primary reduction ratio
Secondary reduction ratio
Final reduction ratio
Gear ratios
1st
2nd
3rd
4th
5th
Reverse
Shift fork to groove clearance

E-19, 28
MIKUNI BSR29
29 mm
(1.14 in)
21G0
1 500 – 100 r/min
13.0 – 1.0 mm
(0.51 – 0.04 in)

(M.J.)

#125

Jet needle

(J.N.)

5DH54-2nd

Needle jet

(N.J.)

P-0M

Pilot jet

(P.J.)

#20

Pilot screw

(P.S.)

1-1/2 turns back

Throttle cable play
Starter (enricher) plunger cable
play

3
(0.12
0.5
(0.02

5 mm
0.2 0 in)
1.0 mm
0.0 4 in)

E-33
←
←

21G1
←
←

←
#
#
PRE-SET
←
←

0.5
(0.020)

SERVICING INFORMATION

ELECTRICAL

Unit: mm (in)

ITEM
Spark plug

SPECIFICATION
NGK: DR7EA
DENSO: X22ESR-U
0.6 0.7
(0.024 0.028)
Over 8 (0.3) at 1 atm.

Type
Gap

Spark performance
Ignition coil resistance

Primary

0.05

Ignition coil primary peak voltage
Generator coil resistance

Pick-up coil peak voltage
Generator no-load voltage
(When engine is cold)
Generator Max. output
Regulated voltage
Starter relay resistance
Battery
Type designation
Capacity
Fuse size

ITEM

HI
LO

Headlight

1.0 Ω

10.5 1 9.0 kΩ
Ω

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Secondary

WATTAGE

Brake light/Taillight
Reverse indicator light
Neutral indicator light

9-33

Pick-up
Charging

120 V and more
80 155 Ω
0.5 1. 2 Ω
4.0 V and more

NOTE

Terminal
Terminal
Plug cap
Terminal
+: B/W -: W/Bl
Bl/Y G/W
Y Y
+: G/W -: Bl/Y

65 V (AC) and more at 5 000 r/min
Approx. 150 W at 5 000 r/min
14.0 15.5 V at 5 000 r/min
3 6 Ω
YTX9-BS
12V 28.8 kC (8 Ah)/10HR
20 A

SPECIFICATION
40
40
21/5
3
3

Unit: W

9-34

SERVICING INFORMATION

BRAKE + WHEEL

Unit: mm (in)

ITEM
Rear brake lever play
Rear brake pedal free travel
Brake disc thickness

Front

Brake disc runout

Master cylinder bore

Front

Master cylinder piston diam.
Brake caliper cylinder bore
Brake caliper piston diam.

Rear

Tire size

Tire tread depth

Front

Front
Rear
Front
Rear
Front
Rear

Wheel axle runout

2.5
(0.098)
0.30
(0.012)
140.7
(5.54)

12.700 12.743
(0.5000 0.5017)
12.657 12.684
(0.4983 0.4994)
32.030 32.080
(1.2610 1. 2630)
31.948 31.998
(1.2578 1.2598)
DOT 4
2.7 m (8.9 ft)
5–4
(0.20 – 0.16)
0
7 40
10 5.5 A T
9 8.0 AT
AT22 7-10 ✩✩
AT20 10-9 ✩

Front

Brake fluid type
Turning radius
Toe-in (with 75 kg, 165 lbs)
Camber
Caster
Wheel rim size

LIMIT

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Brake drum I.D.

STANDARD/SPECIFICATION
3 5
(0.12 0.20)
20 30
(0.79 1.18)
2.8 3.2
(0.110 0.126)

Rear

4.0
(0.16)
4.0
(0.16)
3.0
(0.12)

TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
FRONT
REAR

kPa

kgf/cm2

psi

30
25

0.30
0.25

4.4
3.6

VEHICLE LOAD CAPACITY LIMIT: 110 kg (243 lbs)

SERVICING INFORMATION

FUEL + OIL
ITEM

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Fuel type

SPECIFICATION
Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octane or higher rated
by the Research Method.
Gasoline containing MTBE (MethyI Tertiary
ButyI Ether), less than 10 % ethanol, or less than
5 % methanol with appropriate cosolvents and
corrosion inhibitor is permissible.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
10.6 L
(2.8/2.3 US/lmp gal)
2.6 L
(0.7/0.6 US/lmp gal)
SAE 10W-40, API SF or SG
2 200 ml
Change
(2.3/1.9 US/lmp qt)
2 300 ml
Filter change
(2.4/2.0 US/lmp qt)
2 500 ml
Overhaul
(2.6/2.2 US/lmp qt)
Hypoid gear oil SAE #90, API grade GL-5
190 ml
(6.4/6.7 US/lmp oz)

Fuel tank including reserve

Reserve

Engine oil type
Engine oil capacity

Final gear oil type
Final gear oil capacity

NOTE

E-28, 33

The others

9-35

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

LT-Z250K5 ( 05-MODEL)

10-1

LT-Z250K5 ( 05-MODEL)
10
This chapter describes specifications, service data and servicing procedures which differ from
those of the LT-Z250K4 ( 04-MODEL).

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

NOTE:
* Any differences between the LT-Z250K4 ( 04-MODEL) and LT-Z250K5 ( 05-MODEL) in
specifications and service data are indicated with an asterisk mark (*).
* Please refer to the chapter 1 through 9 for details which are not given in this chapter.

CONTENTS

SPECIFICATIONS ......................................................................................... 10- 2
SERVICE DATA ............................................................................................ 10- 3
TIGHTENING TORQUE................................................................................. 10-10
FRONT BRAKE CALIPER MOUNTING BOLT ............................................. 10-10
FRONT BRAKE HOSE ROUTING ................................................................ 10-11

10-2

LT-Z250K5 ( 05-MODEL)

SPECIFICATIONS
1 720 mm (67.7 in)
1 070 mm (42.1 in)
1 090 mm (42.9 in)
1 135 mm (44.7 in)
830 mm (32.7 in)
810 mm (31.9 in)
230 mm (9.1 in)
810 mm (31.9 in)
166 kg (365 lbs)

ENGINE
Type.....................................................................................................
Number of cylinders ............................................................................
Bore ....................................................................................................
Stroke..................................................................................................
Displacement ......................................................................................
Compression ratio ...............................................................................
Carburetor ...........................................................................................
Air cleaner ...........................................................................................
Starter system.....................................................................................
Lubrication system ..............................................................................
Idle speed ...........................................................................................

Four-stroke, air-cooled, OHC
1
66.0 mm (2.598 in)
72.0 mm (2.835 in)
246 cm3 (15.0 cu. in)
9.2: 1
MIKUNI BSR29, single
Polyurethane foam element
Electric
Wet sump
1 500 – 100 r/min

DRIVE TRAIN
Clutch ..................................................................................................
Transmission .......................................................................................
Gearshift pattern, forward .................................................................
reverse .................................................................
Primary reduction ratio........................................................................
Secondary reduction ratio ...................................................................
Gear ratios, Low ..............................................................................
2nd ...............................................................................
3rd................................................................................
4th ................................................................................
Top ...............................................................................
Reverse........................................................................
Final reduction ratio.............................................................................

Wet multi-plate, automatic, centrifugal type
5-forward and 1-reverse
All up, foot lever operated
Foot/hand operated
3.047 (64/21)
1.133 (17/15)
3.083 (37/12)
1.933 (29/15)
1.388 (25/18)
1.095 (23/21)
0.913 (21/23)
2.833 (34/12)
3.200 (32/10)

CHASSIS
Front suspension.................................................................................
Rear suspension .................................................................................
Front wheel travel................................................................................
Rear wheel travel ................................................................................
Caster .................................................................................................
Trail......................................................................................................
Toe-in ..................................................................................................
Steering angle.....................................................................................
Turning radius .....................................................................................
Front brake ..........................................................................................
Rear brake ..........................................................................................
Front tire size ......................................................................................
Rear tire size .......................................................................................

Independent, double wishbone, coil spring, oil damped
Swingarm type, coil spring, oil damped
160 mm (6.3 in)
170 mm (6.7 in)
7 40 .....................1G
33 mm (1.30 in).....1G
5 mm (0.20 in).......1G
45
2.7 m (8.9 ft)
Disc brake, twin
Drum brake
AT22 7-10 , tubeless
AT20 10-9 , tubeless

ELECTRICAL
Ignition type.........................................................................................
Ignition timing ......................................................................................
Spark plug...........................................................................................
Battery.................................................................................................
Generator ............................................................................................
Main fuse ............................................................................................
Headlight .............................................................................................
Brake light/Taillight ..............................................................................
Neutral indicator light ..........................................................................
Reverse indicator light.........................................................................

Electronic ignition (CDI)
5 B .T.D.C. at 1 500 rpm
NGK DR7EA or DENSO X22ESR-U
12 V 28.8 kC (8 Ah)/10 HR
Three-phase A.C. generator
20/15 A
12 V 40/40 W
12 V 21/5 W
12 V 3 W
12 V 3 W

CAPACITIES
Fuel tank, including reserve..............................................................
reserve .............................................................................
Engine oil, oil change.........................................................................
filter change .....................................................................
overhaul ...........................................................................
Final gear oil change...........................................................................

10.6 L (2.8/2.3 US/Imp gal)
2.6 L (0.7/0.6 US/Imp gal)
2 200 ml (2.3/1.9 US/Imp qt)
2 300 ml (2.4/2.0 US/Imp qt)
2 500 ml (2.6/2.2 US/Imp qt)
190 ml (6.4/6.7 US/Imp oz)

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

DIMENSIONS AND DRY MASS
Overall length ......................................................................................
Overall width .......................................................................................
Overall height ......................................................................................
Wheelbase ..........................................................................................
Front track ...........................................................................................
Rear track............................................................................................
Ground clearance................................................................................
Seat height ..........................................................................................
Dry mass.............................................................................................

LT-Z250K5 ( 05-MODEL)

10-3

SERVICE DATA
VALVE + GUIDE
ITEM
Valve diam.

IN.
EX.

Tappet clearance (when cold)

IN.
EX.

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Valve guide to valve stem
clearance

STANDARD
32
(1.3)
28
(1.1)
0.03 0.08
(0.001 0.003)
0.08 0.13
(0.003 0.005)
0.010 0.037
(0.0004 0.0015)
0.030 0.057
(0.0012 0.0024)

IN.

EX.

Valve stem deflection

IN. & EX.

Valve guide I.D.

IN. & EX.

Valve stem O.D.

IN.

EX.

Valve stem runout

IN. & EX.

Valve head thickness

IN. & EX.

Valve stem end length

Valve seat width

Valve head radial runout

Valve spring free length

5.500
(0.2165
5.475
(0.2156
5.455
(0.2148

IN. & EX.

0.05
(0.002)
0.5
(0.02)
2.5
(0.10)

0.88 1.08
(0.035 0.043)

IN. & EX.

Valve spring tension

0.35
(0.014)

5.512
0.2170)
5.490
0.2161)
5.470
0.2154)

IN. & EX.

Unit: mm (in)
LIMIT

256 294 N
(26.1 30.0 kgf, 57.5 66.1 lbs)
at length 36.6 mm (1.44 in)

0.03
(0.001)
43.0
(1.69)

10-4

LT-Z250K5 ( 05-MODEL)

CAMSHAFT + CYLINDER HEAD
ITEM
Cam height

STANDARD
33.780 33.820
(1.3299 1.3315)
32.990 33.030
(1.2988 1.3004)
0.036 0.066
(0.0014 0.0026)
22.012 22.025
(0.8666 0.8671)
21.959 21.976
(0.8645 0.8652)

IN.
EX.

Camshaft journal oil clearance
Camshaft journal holder I.D.

Camshaft runout
Rocker arm I.D.

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Camshaft journal O.D.

Rocker arm shaft O.D.

12.000
(0.4724
11.977
(0.4715

IN. & EX.
IN. & EX.

Cylinder head cover distortion

CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure

Piston to cylinder clearance

STANDARD

1 400 kPa
(14.0 kgf/cm2, 199 psi)

0.040 0.050
(0.0016 0.0020)
66.000 66.015
(2.5984 2.5990)
65.955 65.970
(2.5966 2.5972)
Measure at 18 mm (0.71 in) from the skirt end.

Piston diam.

Cylinder distortion

Piston ring free end gap

Piston ring end gap

Piston ring to groove clearance

1st

Approx. 8.7 (0.34)

2nd

Approx. 9.0 (0.35)

1st

0.10 0.25
(0.004 0.010)

2nd

0.10 0.25
(0.004 0.010)

1st
2nd

0.10
(0.004)

12.018
0.4731)
11.995
0.4722)

Cylinder head distortion

Cylinder bore

Unit: mm (in)
LIMIT
33.480
(1.3181)
32.690
(1.2870)
0.150
(0.0059)

0.05
(0.002)
0.05
(0.002)

Unit: mm (in)
LIMIT
1 200 kPa
(12.0 kgf/cm2,
171 psi)
0.120
(0.0047)
66.090
(2.6020)
65.880
(2.5937)

0.05
(0.002)
7.0
(0.28)
7.2
(0.28)
0.50
(0.020)
0.5
(0.020)
0.180
(0.007)
0.150
(0.006)

LT-Z250K5 ( 05-MODEL)

CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.

STANDARD
16.006 16.014
(0.6302 0.6305)

Conrod deflection
Conrod big end side clearance
Conrod big end width

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Crank web to web width

0.10 0.45
(0.004 0.018)
17.95 18.00
(0.707 0.709)
53.0 – 0.1
(2.087 – 0.004)

Crankshaft runout

OIL PUMP

ITEM
Oil pressure (at 60 C, 140 F)

CLUTCH

ITEM
Clutch release screw
Drive plate thickness

Drive plate claw width

STANDARD
Above 30 kPa (0.3 kgf/cm2, 4.3 psi)
Below 70 kPa (0.7 kgf/cm2, 9.9 psi)
at 3 000 r/min

STANDARD
1/16 1/8 turn back
2.7 2.9
(0.106 0.114)
11.9 12.0
(0.469 0.472)

Driven plate distortion

Clutch spring free length

Clutch wheel I.D.
Clutch shoe

Clutch engagement r/min
Clutch lock-up r/min

28.9
(1.14)
116.00 116.15
(4.567 4.573)

1 700 2 100 r/min
3 100 3 700 r/min

10-5

Unit: mm (in)
LIMIT
16.040
(0.6315)
3.0
(0.12)
1.0
(0.04)

0.08
(0.003)

LIMIT

Unit: mm (in)
LIMIT
2.4
(0.094)
11.0
(0.433)
0.10
(0.004)
27.5
(1.08)
116.5
(4.59)
No groove at
any part

10-6

LT-Z250K5 ( 05-MODEL)

DRIVE TRAIN
STANDARD
3.047 (64/21)
1.133 (17/15)
3.200 (32/10)
3.083 (37/12)
1.933 (29/15)
1.388 (25/18)
1.095 (23/21)
0.913 (21/23)
2.833 (34/12)
0.10 0.30
(0.004 0.012)
4.50 4.60
(0.169 0.173)
4.30 4.40
(0.169 0.173)
0 10
(0 0.393)
0.03 0.15
(0.001 0.006)
0.05 0.30
(0.002 0.012)

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

ITEM
Primary reduction ratio
Secondary reduction ratio
Final reduction ratio
Gear ratios
1st
2nd
3rd
4th
5th
Reverse
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness

Gearshift lever height

Secondary bevel gear backlash

Rear drive (final) bevel gear backlash

CARBRETOR
ITEM

I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Pilot jet
Pilot screw

0.5
(0.020)

SPECIFICATION

(M.J.)
(J.N.)
(N.J.)
(P.J.)

E-19, 28
MIKUNI BSR29
29 mm
(1.14 in)
21G0
1 500 – 100 r/min
13.0 – 1.0 mm
(0.51 – 0.04 in)
#125
5DH54-2nd
P-0M
#20

(P.S.)

1 and 1/2 turns back

Carburetor type
Bore size

Unit: mm (in) Except ratio
LIMIT

Throttle cable play
Starter (enricher) plunger cable
play

3
(0.12
0.5
(0.02

5 mm
0.20 in)
1.0 mm
0.04 in)

E-33
←
←

21G1
←
←

←

#
#

PRE-SET
←
←

LT-Z250K5 ( 05-MODEL)

ELECTRICAL
ITEM
Spark plug

SPECIFICATION
NGK: DR7EA
DENSO: X22ESR-U
0.6 0.7
(0.024 0.028)
Over 8 (0.3) at 1 atm.

Type
Gap

Spark performance
Ignition coil resistance

Pick-up coil peak voltage
Generator no-load voltage
(When engine is cold)
Generator Max. output
Regulated voltage
Starter relay resistance
Battery
Type designation
Capacity
Fuse size

WATTAGE

ITEM

Headlight

0.05 1.0 Ω

Secondary

10.5 19.0 k Ω
120 V and more
80 155 Ω
0.5 1.2 Ω
4.0 V and more

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Ignition coil primary peak voltage
Generator coil resistance

Primary

Brake light/Taillight
Reverse indicator light
Neutral indicator light

HI
LO

Pick-up
Charging

10-7

Unit: mm (in)
NOTE

Terminal
Terminal
Plug cap
Terminal
+: B/W -: W/Bl
Bl/Y G/W
Y Y
+: G/W -: Bl/Y

65 V (AC) and more at 5 000 r/min
Approx. 150 W at 5 000 r/min
14.0 15.5 V at 5 000 r/min
3 6 Ω
YTX9-BS
12V 28.8 kC (8 Ah)/10HR
20 A

SPECIFICATION
40
40
21/5
3
3

Unit: W

10-8

LT-Z250K5 ( 05-MODEL)

BRAKE + WHEEL
ITEM
Rear brake lever play
Rear brake pedal free travel
Front

Brake disc runout

Front

Brake drum I.D.

Rear

Master cylinder bore

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Brake disc thickness

STANDARD/SPECIFICATION
3 5
(0.12 0.20)
20 30
(0.79 1.18)
2.8 3.2
(0.110 0.126)

Front

Brake caliper cylinder bore

Front

Brake caliper piston diam.

Front

Brake fluid type
Turning radius
Toe-in (with 75 kg, 165 lbs)

Tire size

Tire tread depth

Wheel axle runout

2.5
(0.098)
0.30
(0.012)
140.7
(5.54)

12.700 12.743
(0.5000 0.5017)
12.657 12.684
(0.4983 0.4994)
32.030 32.080
(1.2610 1.2630)
31.948 31.998
(1.2578 1.2598)
DOT 4
2.7 m (8.9 ft)
5–4
(0.20 – 0.16)
0
7 40
10 5.5 AT
9 8.0 AT
AT22 7-10 
AT20 10-9 

Front

Master cylinder piston diam.

Camber
Caster
Wheel rim size

Unit: mm (in)
LIMIT

Front
Rear
Front
Rear

Front
Rear

Rear

4.0
(0.16)
4.0
(0.16)
3.0
(0.12)

TIRE PRESSURE

COLD INFLATION
TIRE PRESSURE
FRONT
REAR

kPa

kgf/cm2

psi

30
25

0.30
0.25

4.4
3.6

VEHICLE LOAD CAPACITY LIMIT: 110 kg (243 lbs)

LT-Z250K5 ( 05-MODEL)

FUEL + OIL
ITEM

Fuel type

including
reserve
Reserve

10.6 L
(2.8/2.3 US/lmp gal)

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Fuel tank capacity

Engine oil type
Engine oil capacity

Final gear oil type
Final gear oil capacity

2.6 L
(0.7/0.6 US/lmp gal)
SAE 10W-40, API SF or SG
2 200 ml
Change
(2.3/1.9 US/lmp qt)
2 300 ml
Filter change
(2.4/2.0 US/lmp qt)
2 500 ml
Overhaul
(2.6/2.2 US/lmp qt)
Hypoid gear oil SAE #90, API grade GL-5
190 ml
(6.4/6.7 US/lmp oz)

NOTE

E-28, 33

The others

10-9

10-10

LT-Z250K5 ( 05-MODEL)

TIGHTENING TORQUE
CHASSIS
ITEM

kgf-m
2.3
2.3
4.9
6.5
6.5
13.8
* 6.0
2.9

6.0

43.5

29
29
6.0
26
16
18
18
23
10
23
23
23
26
55
78
60
85
11
11
60

2.9
2.9
0.6
2.6
1.6
1.8
1.8
2.3
1.0
2.3
2.3
2.3
2.6
5.5
7.8
6.0
8.5
1.1
1.0
6.0

21.0
21.0
4.4
19.0
11.6
13.0
13.0
16.5
7.0
16.5
16.5
16.5
19.0
40.0
55.0
43.5
61.5
8.0
8.0
43.5

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

N•m
23
23
49
65
65
138
* 60
29

FRONT BRAKE CALIPER MOUNTING BOLT
Apply THREAD LOCK SUPER 1360 to the caliper mounting bolts before tightening them.
 99000-32130: THREAD LOCK SUPER 1360

lb-ft
16.5
16.5
35.5
47.0
47.0
99.9
* 43.5
21.0

Front
brake
pipe

0 –5

VIEW D

Foward

VIEW C

Mark

Cable guide

VIEW A

White mark

Pass the brake hose
in front of
the wiring harness.

VIEW B

White mark

Foward

SECT F F

Punched mark

Clamp firmly.

Pass the brake pipe
behind the reverse cable.

Reverse cable

Mark

Cable guide

Mark

The white mark faces front side.

Front brake pipe

Pass the brake hose
in front of
the throttle cable.

Wiring harness

Clamp
the hose
firmly.

Brake hose guide

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Throttle cable

Front Brake hose

After the brake hose union
touching to the stopper,
tighten the union bolt.

(LH)

SECT E E

Clamp firmly.

After the brake hose union
touching to the stopper,
tighten the union bolt.

(RH)

LT-Z250K5 ( 05-MODEL)
10-11

FRONT BRAKE HOSE ROUTING

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

LT-Z250K6 ( 06-MODEL)

11-1

LT-Z250K6 ( 06-MODEL)

This chapter describes specifications, service data and servicing procedures which differ from
those of the LT-Z250K5 ( 05-MODEL).

87 tS
7- h
99 ar
k
9- .c
56 o
m
86

NOTE:
* Any differences between the LT-Z250K5 ( 05-MODEL) and LT-Z250K6 ( 06-MODEL) in
specifications and service data are indicated with an asterisk mark (*).
* Please refer to the chapter 1 through 10 for details which are not given in this chapter.

CONTENTS

SPECIFICATIONS ......................................................................................... 11- 2
SERVICE DATA ............................................................................................ 11- 3

11-2

LT-Z250K6 ( 06-MODEL)

SPECIFICATIONS
1 720 mm (67.7 in)
1 070 mm (42.1 in)
1 090 mm (42.9 in)
1 135 mm (44.7 in)
830 mm (32.7 in)
810 mm (31.9 in)
230 mm (9.1 in)
810 mm (31.9 in)
166 kg (365 lbs)

Four-stroke, air-cooled, OHC
1
66.0 mm (2.598 in)
72.0 mm (2.835 in)
246 cm3 (15.0 cu. in)
9.2 : 1
MIKUNI BSR29, single
Polyurethane foam element
Electric
Wet sump
1 500 – 100 r/min

Independent, double wishbone, coil spring, oil damped
Swingarm type, coil spring, oil damped
160 mm (6.3 in)
170 mm (6.7 in)
7 40 ............................1G
33 mm (1.30 in)............1G
5 mm (0.20 in)..............1G
45
2.7 m (8.9 ft)
Disc brake, twin
Drum brake
AT22 7-10✩✩, tubeless
AT20 10- 9 ✩, tubeless

Electronic ignition (CDI)
5 B .T.D.C. at 1 500 rpm
NGK DR7EA or DENSO X22ESR-U
12 V 28.8 kC (8 Ah)/10 HR
Three-phase A.C. generator
20/15 A
12 V 40/40 W
12 V 21/5 W
12 V 3 W
12 V 3 W

10.6 L (2.8/2.3 US/Imp gal)
2.6 L (0.7/0.6 US/Imp gal)
2 200 ml (2.3/1.9 US/Imp qt)
2 300 ml (2.4/2.0 US/Imp qt)
2 500 ml (2.6/2.2 US/Imp qt)
190 ml (6.4/6.7 US/Imp oz)

87 tS
7- h
99 ar
k
9- .c
56 o
m
86

LT-Z250K6 ( 06-MODEL)

11-3

SERVICE DATA
VALVE + GUIDE
ITEM
Valve diam.

IN.
EX.

Tappet clearance (when cold)

IN.
EX.
IN.

87 tS
7- h
99 ar
k
9- .c
56 o
m
86

Valve guide to valve stem
clearance

STANDARD
32
(1.3)
28
(1.1)
0.03 0.08
(0.001 0.003)
0.08 0.13
(0.003 0.005)
0.010 0.037
(0.0004 0.0015)
0.030 0.057
(0.0012 0.0024)

EX.

Valve stem deflection

IN. & EX.

Valve guide I.D.

IN. & EX.

Valve stem O.D.

IN.

EX.

Valve stem runout

IN. & EX.

Valve head thickness

IN. & EX.

Valve stem end length

Valve seat width

Valve head radial runout

Valve spring free length

5.500
(0.2165
5.475
(0.2156
5.455
(0.2148

IN. & EX.

0.05
(0.002)
0.5
(0.02)
2.5
(0.10)

0.88 1.08
(0.035 0.043)

IN. & EX.

Valve spring tension

0.35
(0.014)

5.512
0.2170)
5.490
0.2161)
5.470
0.2154)

IN. & EX.

Unit: mm (in)
LIMIT

256 294 N
(26.1 30.0 kgf, 57.5 66.1 lbs)
at length 36.6 mm (1.44 in)

0.03
(0.001)
43.0
(1.69)

11-4

LT-Z250K6 ( 06-MODEL)

CAMSHAFT + CYLINDER HEAD
ITEM
Cam height

STANDARD
33.780 33.820
(1.3299 1.3315)
32.990 33.030
(1.2988 1.3004)
0.036 0.066
(0.0014 0.0026)
22.012 22.025
(0.8666 0.8671)
21.959 21.976
(0.8645 0.8652)

IN.
EX.

Camshaft journal oil clearance
Camshaft journal holder I.D.

Camshaft runout
Rocker arm I.D.

87 tS
7- h
99 ar
k
9- .c
56 o
m
86

Camshaft journal O.D.

Rocker arm shaft O.D.

12.000
(0.4724
11.977
(0.4715

IN. & EX.
IN. & EX.

Cylinder head cover distortion

CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure

Piston to cylinder clearance

STANDARD

1 400 kPa
(14.0 kgf/cm2, 199 psi)

0.040 0.050
(0.0016 0.0020)
66.000 66.015
(2.5984 2.5990)
65.955 65.970
(2.5966 2.5972)
Measure at 18 mm (0.71 in) from the skirt end.

Piston diam.

Cylinder distortion

Piston ring free end gap

Piston ring end gap

Piston ring to groove clearance

1st

Approx. 8.7 (0.34)

2nd

Approx. 9.0 (0.35)

1st

0.10 0.25
(0.004 0.010)

2nd

0.10 0.25
(0.004 0.010)

1st
2nd

Piston ring groove width

1st
2nd
Oil

1.01
(0.0398
1.21
(0.0476
2.01
(0.0791

0.10
(0.004)

12.018
0.4731)
11.995
0.4722)

Cylinder head distortion

Cylinder bore

Unit: mm (in)
LIMIT
33.480
(1.3181)
32.690
(1.2870)
0.150
(0.0059)

1.03
0.0406)
1.23
0.0484)
2.03
0.0799)

0.05
(0.002)
0.05
(0.002)

Unit: mm (in)
LIMIT
1 200 kPa
(12.0 kgf/cm2,
171 psi)
0.120
(0.0047)
66.090
(2.6020)
65.880
(2.5937)

0.05
(0.002)
7.0
(0.28)
7.2
(0.28)
0.50
(0.020)
0.50
(0.020)
0.180
(0.007)
0.150
(0.006)

LT-Z250K6 ( 06-MODEL)

ITEM
Piston ring thickness

1st
2nd

Piston pin bore
Piston pin O.D.

STANDARD
0.97 0.99
(0.038 0.039)
1.17 1.19
(0.046 0.047)
16.002 16.008
(0.6300 0.6302)
15.992 16.000
(0.6296 0.6299)

CONROD + CRANKSHAFT
STANDARD
16.006 16.014
(0.6302 0.6305)

87 tS
7- h
99 ar
k
9- .c
56 o
m
86

ITEM
Conrod small end I.D.
Conrod deflection

Conrod big end side clearance
Conrod big end width

Crank web to web width

0.10 0.45
(0.004 0.018)
17.95 18.00
(0.707 0.709)
53.0 – 0.1
(2.087 – 0.004)

Crankshaft runout

OIL PUMP

ITEM
Oil pressure (at 60 C, 140 F)

CLUTCH

ITEM
Clutch release screw
Drive plate thickness

Drive plate claw width

STANDARD
Above 30 kPa (0.3 kgf/cm2, 4.3 psi)
Below 70 kPa (0.7 kgf/cm2, 9.9 psi)
at 3 000 r/min

STANDARD
1/16 1/8 turn back
2.7 2.9
(0.106 0.114)
11.9 12.0
(0.469 0.472)

Driven plate distortion
Clutch spring free length
Clutch wheel I.D.

28.9
(1.14)
116.00 116.15
(4.567 4.573)

Clutch shoe
Clutch engagement r/min
Clutch lock-up r/min

1 700 2 100 r/min
3 100 3 700 r/min

11-5

LIMIT

16.030
(0.6311)
15.980
(0.6291)
Unit: mm (in)
LIMIT
16.040
(0.6315)
3.0
(0.12)
1.0
(0.04)

0.08
(0.003)

LIMIT

Unit: mm (in)
LIMIT
2.4
(0.094)
11.0
(0.433)
0.10
(0.004)
27.5
(1.08)
116.5
(4.59)
No groove at
any part

11-6

LT-Z250K6 ( 06-MODEL)

87 tS
7- h
99 ar
k
9- .c
56 o
m
86

ITEM
Primary reduction ratio
Secondary reduction ratio
Final reduction ratio
Gear ratios
1st
2nd
3rd
4th
5th
Reverse
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness

Gearshift lever height

Secondary bevel gear backlash

Rear drive (final) bevel gear backlash

CARBRETOR
ITEM

(M.J.)
(J.N.)
(N.J.)
(P.J.)

E-19, 28
MIKUNI BSR29
29 mm
(1.14 in)
21G0
1 500 – 100 r/min
13.0 – 1.0 mm
(0.51 – 0.04 in)
#125
5DH54-2nd
P-0M
#20

(P.S.)

1 and 1/2 turns back

I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Pilot jet
Pilot screw

0.5
(0.020)

SPECIFICATION

Carburetor type
Bore size

Unit: mm (in) Except ratio
LIMIT

Throttle cable play
Starter (enricher) plunger cable
play

3
(0.12
0.5
(0.02

5 mm
0.20 in)
1.0 mm
0.04 in)

E-33
←
←

21G1
←
←

←

#
#

PRE-SET
←
←

LT-Z250K6 ( 06-MODEL)

ELECTRICAL
ITEM
Spark plug

SPECIFICATION
NGK: DR7EA
DENSO: X22ESR-U
0.6 0.7
(0.024 0.028)
Over 8 (0.3) at 1 atm.

Type
Gap

Spark performance
Ignition coil resistance

Pick-up coil peak voltage
Generator no-load voltage
(When engine is cold)
Generator Max. output
Regulated voltage
Starter relay resistance
Battery
Type designation
Capacity
Fuse size

WATTAGE

ITEM

Headlight

0.05 1.0 Ω

Secondary

10.5 19.0 k Ω
120 V and more
80 155 Ω
0.5 1.2 Ω
4.0 V and more

87 tS
7- h
99 ar
k
9- .c
56 o
m
86

Ignition coil primary peak voltage
Generator coil resistance

Primary

Brake light/Taillight
Reverse indicator light
Neutral indicator light

HI
LO

Pick-up
Charging

11-7

Unit: mm (in)
NOTE

Terminal
Terminal
Plug cap
Terminal
+: B/W -: W/Bl
Bl/Y G/W
Y Y
+: G/W -: Bl/Y

65 V (AC) and more at 5 000 r/min
Approx. 150 W at 5 000 r/min
14.0 15.5 V at 5 000 r/min
3 6 Ω
YTX9-BS
12V 28.8 kC (8 Ah)/10HR
20 A

SPECIFICATION
40
40
21/5
3
3

Unit: W

11-8

LT-Z250K6 ( 06-MODEL)

BRAKE + WHEEL
ITEM
Rear brake lever play
Rear brake pedal free travel
Front

Brake disc runout

Front

Brake drum I.D.

Rear

Master cylinder bore

87 tS
7- h
99 ar
k
9- .c
56 o
m
86

Brake disc thickness

STANDARD/SPECIFICATION
3 5
(0.12 0.20)
20 30
(0.79 1.18)
2.8 3.2
(0.110 0.126)

Front

Brake caliper cylinder bore

Front

Brake caliper piston diam.

Front

Brake fluid type
Turning radius
Toe-in (with 75 kg, 165 lbs)
Camber
Caster
Wheel rim size

Tire size

Tire tread depth

Wheel axle runout

2.5
(0.098)
0.30
(0.012)
140.7
(5.54)

12.700 12.743
(0.5000 0.5017)
12.657 12.684
(0.4983 0.4994)
32.030 32.080
(1.2610 1.2630)
31.948 31.998
(1.2578 1.2598)
DOT 4
2.7 m (8.9 ft)
5–4
(0.20 – 0.16)
0
7 40
10 5.5 AT
9 8.0 AT
AT22 7-10 ✩✩
AT20 10-9 ✩

Front

Master cylinder piston diam.

Unit: mm (in)
LIMIT

Front
Rear
Front
Rear

Front
Rear

Rear

4.0
(0.16)
4.0
(0.16)
3.0
(0.12)

TIRE PRESSURE

COLD INFLATION
TIRE PRESSURE
FRONT
REAR

kPa

kgf/cm2

psi

30
25

0.30
0.25

4.4
3.6

VEHICLE LOAD CAPACITY LIMIT: 110 kg (243 lbs)

LT-Z250K6 ( 06-MODEL)

FUEL + OIL
ITEM
Fuel type

87 tS
7- h
99 ar
k
9- .c
56 o
m
86

Fuel tank capacity including
reserve

SPECIFICATION
Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octane or higher rated
by the Research Method.
Gasoline containing MTBE (MethyI Tertiary
ButyI Ether), less than 10% ethanol, or less than
5% methanol with appropriate cosolvents and
corrosion inhibitor is permissible.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
10.6 L
(2.8/2.3 US/lmp gal)
2.6 L
(0.7/0.6 US/lmp gal)
* SAE 10W-40, API SF/SG or SH/SJ with JASO MA
2 200 ml
Change
(2.3/1.9 US/lmp qt)
2 300 ml
Filter change
(2.4/2.0 US/lmp qt)
2 500 ml
Overhaul
(2.6/2.2 US/lmp qt)
Hypoid gear oil SAE #90, API grade GL-5
190 ml
(6.4/6.7 US/lmp oz)

Reserve

Engine oil type
Engine oil capacity

Final gear oil type
Final gear oil capacity

NOTE

E-28, 33

The others

11-9

LT-Z250K7 ( 07-MODEL)

12-1

LT-Z250K7 ( 07-MODEL)

NOTE:
* The specification and service data are the same as the K6-MODEL

CONTENTS

87 tS
7- h
99 ar
k
9- .c
56 o
m
86

I NFORMATION LABEL INSTALLATION (For E-33) ................................... 12- 2

12- 2

LT-Z250K7 ( 07-MODEL)

INFORMATION LABEL INSTALLATION (For E-33)

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

10 ±

LABEL

Frame LH side

–2–

LT-Z250K8 ( 08-MODEL)

13-1

LT-Z250K8 ( 08-MODEL)

NOTE:
* The specification and service data are the same as the K7-MODEL

CONTENTS

87 tS
7- h
99 ar
k
9- .c
56 o
m
86

I NFORMATION LABEL ............................................................................... 13- 2

13-2

LT-Z250K8 ( 08-MODEL)

INFORMATION LABELS
No.

APPLIED SPECIFICATION
E-19
E-28
E-33

LABEL or PLATE NAME

Certification plate E

Information label E

Gearshift pattern label E

Gearshift pattern label E/F

Tire air pressure label E

Tire air pressure label and warning no-passenger label F

General warning label E

General warning label F

Warning no-passenger label E

Age, 16 Iabel E

Age, 16 Iabel F

Manual notice label E

Gearshift label E

Gearshift label F

ICES Canada label E/F

Compliance label E

EC approval mark

Compliance label

A
A
A
A

A
A

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

* E-28: Fuel caution label enclosed.
E: English
F: French
A: Attached

Left side frame

Front of left side frame

–2–

A
A

1 LT-Z250K9 (’09 MODEL)

14-1

LT-Z250K9 (’09 MODEL)

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

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016'
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KPURGEKHKECVKQPUCTGENGCT[KPFKECVGFYKVJCPCUVGTKUM OCTM
2NGCUGTGHGTVQVJGECRVGTUVJTQWIJHQTFGVCKNUYJKEJCTGPQVIKXGPKPVJKUEJCRVGT

CONTENTS

PAGE

52'%+(+%#6+105
5'48+%'#
(7'.6#0-%105647%6+10
%#4$74'614

+0(14/#6+10.#$'.5

14- 2

LT-Z250K9 ( 09-MODEL)

SPECIFICATIONS
1 720 mm (67.7 in)
1 070 mm (42.1 in)
1 090 mm (42.9 in)
1 135 mm (44.7 in)
830 mm (32.7 in)
810 mm (31.9 in)
230 mm (9.1 in)
810 mm (31.9 in)
177 kg (390 lbs)

ENGINE
Type.....................................................................................................
Number of cylinders ............................................................................
Bore.....................................................................................................
Stroke ..................................................................................................
Displacement ......................................................................................
Compression ratio ...............................................................................
Carburetor ...........................................................................................
Air cleaner ...........................................................................................
Starter system .....................................................................................
Lubrication system ..............................................................................
Idle speed............................................................................................

4-stroke, air-cooled, OHC
1
66.0 mm (2.598 in)
72.0 mm (2.835 in)
246 cm3 (15.0 cu. in)
9.2 : 1
MIKUNI BSR29, single
Polyurethane foam element
Electric
Wet sump
1 500 ± 100 r/min

DRIVE TRAIN
Clutch ..................................................................................................
Transmission .......................................................................................
Gearshift pattern, forward..................................................................
reverse..................................................................
Primary reduction ratio ........................................................................
Gear ratios, Low ................................................................................
2nd ................................................................................
3rd .................................................................................
4th .................................................................................
Top.................................................................................
Reverse .........................................................................
Secondary reduction ratio ...................................................................
Final reduction ratio.............................................................................

Wet multi-plate, automatic, centrifugal type
5-speed forward with reverse
All up, foot operated
Foot/hand operated
3.047 (64/21)
3.083 (37/12)
1.933 (29/15)
1.388 (25/18)
1.095 (23/21)
0.913 (21/23)
2.833 (34/12)
1.133 (17/15)
3.200 (32/10)

CHASSIS
Front suspension.................................................................................
Rear suspension .................................................................................
Front wheel travel ................................................................................
Rear wheel travel ................................................................................
Caster..................................................................................................
Trail......................................................................................................
Toe-in...................................................................................................
Steering angle .....................................................................................
Turning radius......................................................................................
Front brake ..........................................................................................
Rear brake...........................................................................................
Front tire ..............................................................................................
Rear tire ..............................................................................................

Independent, double wishbone, coil spring, oil damped
Swingarm type, coil spring, oil damped
160 mm (6.3 in)
170 mm (6.7 in)
7° 40’
33 mm (1.30 in)
5 mm (0.20 in)
45° (right & left)
2.7 m (8.9 ft)
Disc brake, twin
Drum brake
AT22 × 7-10 °°, tubeless
AT20 × 10- 9 °, tubeless

ELECTRICAL
Ignition type .........................................................................................
Ignition timing ......................................................................................
Spark plug ...........................................................................................
Battery.................................................................................................
Generator ............................................................................................
Main fuse.............................................................................................
Fuse ....................................................................................................
Headlight .............................................................................................
Brake/Tail light .....................................................................................
Neutral indicator light...........................................................................
Reverse indicator light .........................................................................

Electronic ignition (CDI)
5° B.T.D.C. at 1 500 r/min
NGK DR7EA or DENSO X22ESR-U
12 V 28.8 kC (8 Ah)/10 HR
Three-phase A.C. generator
20 A
15 A
12 V 40/40 W
12 V 21/5 W
12 V 3 W
12 V 3 W

CAPACITIES
Fuel tank, including reserve ..............................................................*
reserve .............................................................................*
Engine oil, oil change.........................................................................
with filter change ..............................................................
overhaul............................................................................
Final gear oil........................................................................................

9.7 L (2.6/2.1 US/Imp gal)
2.1 L (0.6/0.5 US/Imp gal)
2 200 ml (2.3/1.9 US/Imp qt)
2 300 ml (2.4/2.0 US/Imp qt)
2 500 ml (2.6/2.2 US/Imp qt)
190 ml (6.4/6.7 US/Imp oz)

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

DIMENSIONS AND CURB MASS
Overall length ......................................................................................
Overall width........................................................................................
Overall height ......................................................................................
Wheelbase ..........................................................................................
Front track ...........................................................................................
Rear track............................................................................................
Ground clearance................................................................................
Seat height ..........................................................................................
* Curb mass ........................................................................................

LT-Z250K9 ( 09 MODEL)

SERVICE DATA
CARBRETOR
SPECIFICATION

ITEM

* E-28, 33
←

(M.J.)
(J.N.)
(N.J.)
(P.J.)

* E-19
MIKUNI BSR29
29 mm
(1.14 in)
21G0
1 500 ± 100 r/min
13.0 ± 1.0 mm
(0.51 ± 0.04 in)
#125
5DH54-2nd
P-0M
#20

(P.S.)

1 and 1/2 turns back

PRE-SET

3 – 5 mm
(0.12 – 0.20 in)
0.5 – 1.0 mm
(0.02 – 0.04 in)

←

Carburetor type
Bore size

Main jet
Jet needle
Needle jet
Pilot jet
Pilot screw

Throttle cable play

Starter (enricher) plunger cable
play

FUEL + OIL

ITEM

Fuel type

21G1
←
←

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

I.D. No.
Idle r/min
Float height

←

Fuel tank capacity including
reserve
Reserve

Engine oil type
Engine oil capacity

Final gear oil type
Final gear oil capacity

←

#
#

SPECIFICATION
Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octane or higher rated
by the Research Method.
Gasoline containing MTBE (MethyI Tertiary
ButyI Ether), less than 10% ethanol, or less than
5% methanol with appropriate cosolvents and
corrosion inhibitor is permissible.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
* 9.7 L
(2.6/2.1 US/lmp gal)
* 2.1 L
(0.6/0.5 US/lmp gal)
SAE 10W-40, API SF/SG or SH/SJ with JASO MA
2 200 ml
Change
(2.3/1.9 US/lmp qt)
2 300 ml
Filter change
(2.4/2.0 US/lmp qt)
2 500 ml
Overhaul
(2.6/2.2 US/lmp qt)
Hypoid gear oil SAE #90, API grade GL-5
190 ml
(6.4/6.7 US/lmp oz)

←

NOTE

E-28, 33

E-19

14-3

14- 4

LT-Z250K9 ( 09-MODEL)

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

FUEL TANK CONSTRUCTION

1
2
3
4
5
6
7

Fuel tank
Fuel cap
Breather hose
Gasket
Gasket
Fuel valve
Fuel hose

LT-Z250K9 ( 09 MODEL)

CARBURETOR
PILOT SCREW REMOVAL (For E-28, 33)
Because harsh cleaning solvents can damage the O-ring seals
in the pilot system, the pilot system components should be
removed before cleaning.

1
2
3
4

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

• Use a 1/8” size drill bit with a drill-stop to remove the pilot
screw plug. Set the drill-stop 4 mm (0.16 in) from the end of
the bit to prevent drilling into the pilot screw. Carefully drill
through the plug.
• Thread a self-tapping sheet metal screw into the plug. Pull on
the screw head with pliers to remove the plug. Carefully clean
any metal shavings from the area.
• Slowly turn the pilot screw clockwise and count the number of
turns until the screw is lightly seated. Make a note of how
many turns were made so the screw can be reset correctly
after cleaning.
• Remove the pilot screw along with the spring, washer and Oring.
Drill-stop
Plug
Pilot screw
Carburetor body

PILOT SCREW REASSEMBLY (For E-28, 33)
• After cleaning, install the pilot screw 1 to the original setting
by turning the screw in until it lightly seats, and then backing it
out the same number of turns counted during disassembly.
• Install a new plug by tapping it into place with a punch.

1 Pilot screw
2 Carburetor body

Replace the removed O-ring with a new one.

14-5

14- 6 LT-Z250K9 ( 09-MODEL)

INFORMATION LABELS

8 7 tS
7- h
99 ar
k
9- .c
56 o
m
86

Information label (E-28)
Certification label (E-33)

Front of frame right side

FWD

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2004 Suzuki 250 LTZ Quad Sport Service Manual

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