2004 Suzuki 250 LTZ Quad Sport Service Manual

User Manual: 2004 Suzuki 250 LTZ Quad Sport Service Manual

Open the PDF directly: View PDF PDF.
Page Count: 325 [warning: Documents this large are best viewed by clicking the View PDF Link!]

GROUP INDEX
GENERAL INFORMATION 1
PERIODIC MAINTENANCE 2
ENGINE 3
DRIVE TRAIN 4
FUEL SYSTEM 5
LUBRICATION SYSTEM 6
CHASSIS 7
ELECTRICAL SYSTEM 8
SERVICING INFORMATION 9
FOREWORD
This manual contains an introductory description on
the SUZUKI LT-Z250 and procedures for its inspec-
tion, 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 mainte-
nance. 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 reli-
able service.
' COPYRIGHT SUZUKI MOTOR CORPORATION 2003
* This manual has been prepared on the basis
of the latest specifications at the time of publi-
cation. If modifications have been made since
then, differences may exist between the con-
tent 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 motorcy-
cle dealer to help you.
Inexperienced mechanics or mechanics
without the proper tools and equipment
may not be able to properly perform the
services described in this manual.
Improper repair may result in injury to the
mechanic and may render the vehicle
unsafe for the rider.
99500-42175-03E
PartShark.com
877-999-5686
03 ENGINE.book Page 105 Tuesday, February 28, 2006 3:03 PM
PartShark.com
877-999-5686
03 ENGINE.book Page 105 Tuesday, February 28, 2006 3:03 PM
SUPPLEMENTS
LT-Z250K5 (05-MODEL) 10
LT-Z250K6 (06-MODEL) 11
12
LT-Z250K7 (07-MODEL)
LT-Z250K8 (08-MODEL) 13
14
LT-Z250K9 (09-MODEL)
PartShark.com
877-999-5686
HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE LOOKING FOR:
1. The text of this manual is divided into sections.
2. The section titles are listed in the GROUP INDEX.
3. Holding the manual as shown at the right will allow you to find
the first page of the section easily.
4. The contents are listed on the first page of each section to
help you find the item and page you need.
COMPONENT PARTS AND WORK TO BE DONE
Under the name of each system or unit there is an exploded view which provides work instructions and other
service information (e.g.; tightening torque, lubricating points and locking agent points).
Example: Rear suspension
ITEM N•m kgf-m lb-ft
78 7.8 55.0
60 6.0 43.5
85 8.5 61.5
60 6.0 43.5
65 6.5 47.0
Rear shock absorber
Swingarm
Bearing
Rear shock absorber mounting nut (Upper)
Rear shock absorber mounting nut (Lower)
Swingarm pivot nut
Axle housing mounting nut (RH)
Axle housing bolt
Axle housing mounting nut (LH)
PartShark.com
877-999-5686
SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servic-
ing. The meaning of each symbol is also included in the table.
SYMBOL DEFINITION SYMBOL DEFINITION
Torque control required.
Data beside it indicates specified
torque.
Apply THREAD LOCK SUPER 1303.
99000-32030
Indicates service data. Apply THREAD LOCK SUPER1322.
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 SUPER1360.
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.
Apply SUZUKI BOND 1216B.
99000-31230
H/O
W
1216B
PartShark.com
877-999-5686
PartShark.com
877-999-5686
1
GENERAL INFORMATION 1-1
GENERAL INFORMATION
CONTENTS
WARNING/CAUTION/NOTE .........................................................................1- 2
GENERAL PRECAUTIONS ...........................................................................1- 2
SUZUKI LT-Z250K4 (2004-MODEL) .............................................................1- 4
SERIAL NUMBER LOCATION ......................................................................1- 4
FUEL AND OIL RECOMMENDATION ..........................................................1- 4
FUEL (FOR CANADA AND USA) ..........................................................1- 4
FUEL (FOR THE OTHER COUNTRIES) ................................................1- 4
ENGINE OIL (FOR USA) ........................................................................1- 5
ENGINE OIL (FOR THE OTHER COUNTRIES) ....................................1- 5
REAR DRIVE GEAR OIL .......................................................................1- 5
BRAKE FLUID ........................................................................................1- 5
BREAK-lN PROCEDURES ...........................................................................1- 5
INFORMATION LABELS ...............................................................................1- 6
SPECIFICATIONS .........................................................................................1- 7
DIMENSIONS AND DRY MASS ............................................................1- 7
ENGINE ..................................................................................................1- 7
DRIVE TRAIN .........................................................................................1- 7
CHASSIS ................................................................................................1- 8
ELECTRICAL .........................................................................................1- 8
CAPACITIES ..........................................................................................1- 8
COUNTRY AND AREA CODES ....................................................................1- 9
PartShark.com
877-999-5686
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 mes-
sages highlighted by these signal words.
!
Indicates a potential hazard that could result in death or injury.
"
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 out-
doors.
* When handling toxic or flammable materials, make sure that the area you work in is well ven-
tilated 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.
PartShark.com
877-999-5686
GENERAL INFORMATION 1-3
"
* If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva-
lent.
* 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 bat-
tery 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 speci-
fied 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, bat-
teries and tires.
* To protect the earths natural resources, properly dispose of used vehicles and parts.
PartShark.com
877-999-5686
1-4 GENERAL INFORMATION
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% etha-
nol. Gasoline/alcohol fuel may contain up to 5% methanol if appropriate cosolvents and corrosion inhibi-
tors 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.
PartShark.com
877-999-5686
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 alter-
native according to the chart.
ENGINE OIL (FOR THE OTHER COUNTRIES)
Use a premium quality 4-stroke motor oil to ensure longer ser-
vice life of the vehicles. Use only oils that meet API service clas-
sifications 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 avail-
able, 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 0C (32 F).
BRAKE FLUID
#Specification and classification: DOT 4
!
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 toBREAK-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.
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.
PartShark.com
877-999-5686
1-6 GENERAL INFORMATION
INFORMATION LABELS
* E-28: Fuel caution label enclosed.
E: English
F: French
A: Attached
No. LABEL or PLATE NAME APPLIED SPECIFICATION
E-19 E-28 E-33
1Certification plate
EAA
2Information label
EA
3Gearshift pattern label
EA
4Gearshift pattern label
E/
FA
5Tire air pressure label
EAAA
6Tire air pressure label and warning no-passenger label
FA
7General warning label
EAAA
8General warning label
FA
9Warning no-passenger label
EAAA
0Age, 16 Iabel
EAAA
AAge, 16 Iabel
FA
BManual notice label
EA
CGearshift label
EAAA
DGearshift label
FA
EICES Canada label
E/
F
FCompliance label
EA
GEC approval mark A A
Front of left side frame
Left side frame
PartShark.com
877-999-5686
GENERAL INFORMATION 1-7
SPECIFICATIONS
DIMENSIONS AND DRY MASS
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)
ENGINE
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)
PartShark.com
877-999-5686
1-8 GENERAL INFORMATION
CHASSIS
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
ELECTRICAL
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.
PartShark.com
877-999-5686
GENERAL INFORMATION 1-9
COUNTRY AND AREA CODES
The following codes stand for the applicable countries and areas:
CODE COUNTRY OR AREA
E-19
E-28
E-33
EU
Canada
USA and California
PartShark.com
877-999-5686
PartShark.com
877-999-5686
2
6
PERIODIC MAINTENANCE 2-1
CONTENTS
PERIODIC MAINTENANCE
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
PartShark.com
877-999-5686
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
I = Inspect and adjust, clean, lubricate or replace as necessary
R = Replace
T = Tighten
C = Clean
L = Lubricate
Interval Initial Every Every
Item 1 month 3 months 6 months
Air cleaner C C
Exhaust pipe nuts and muffler bolts T T T
Valve clearance I I I
Spark plug  I
Replace every 18 months.
Spark arrester C
Engine idle speed I I I
Throttle cable play I I I
Fuel line I I
Replace every 4 years.
Engine oil and oil filter R R
Final gear oil  I
Replace every 2 years.
Clutch   I
Brakes I I I
Brake fluid I I
Replace every 2 years.
Brake hose  I
Replace every 4 years.
Tires I I
Suspensions   I
Steering I I I
Chassis bolts and nuts T T T
General lubrications L L L
PartShark.com
877-999-5686
PERIODIC MAINTENANCE 2-3
MAINTENANCE AND TUNE-UP PROCEDURES
This section describes the servicing procedures for each item
mentioned in the Periodic Maintenance chart.
AIR CLEANER
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.
Clean every 3 months.
PartShark.com
877-999-5686
2-4 PERIODIC MAINTENANCE
Fill a wash pan of a proper size with a non-flammable clean-
ing 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.
ANon-flammable cleaning solvent
BMotor oil SAE #30 or SAE 10W-40
"
Remove the drain cap
7 of the air cleaner box to allow any
water to drain out.
* Inspect the air cleaner element for tears. A torn ele-
ment 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 with-
out 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!
PartShark.com
877-999-5686
PERIODIC MAINTENANCE 2-5
EXHAUST PIPE NUTS AND MUFFLER
BOLTS
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.
#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
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.
Tighten initially at 1 month and every 3 months there-
after.
Inspect initially at 1 month and every 3 months there-
after.
PartShark.com
877-999-5686
2-6 PERIODIC MAINTENANCE
Remove the valve inspection caps
3.
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 compres-
sion 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 speci-
fied 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
"
#Valve clearance adjuster locknut:
14 N•m (1.4 kgf-m, 10.0 lb-ft)
Install the spark plug, valve timing inspection plug and gener-
ator 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)
Securely tighten the locknut after completing adjust-
ment.
PartShark.com
877-999-5686
PERIODIC MAINTENANCE 2-7
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.
SPARK PLUG
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 electrodes
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.
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.
Inspect every 6 months.
Replace every 18 months.
NGK DENSO
Standard DR7EA X22ESR-U
Colder type DR8EA X24ESR-U
PartShark.com
877-999-5686
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
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, dam-
aged threads, etc.
"
SPARK PLUG INSTALLATION
"
#Spark plug: 18 N•m (1.8 kgf-m, 13.0 lb-ft)
FUEL LINE
Inspect the fuel hose for damage and fuel leakage. If any
damages are found, replace the fuel hose with a new one.
0.6  0.7 mm
(0.024  0.028 in)
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 dam-
age may result.
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.
Inspect every 3 months.
Replace every 4 years.
PartShark.com
877-999-5686
PERIODIC MAINTENANCE 2-9
THROTTLE CABLE PLAY
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)
After adjusting the throttle cable play, tighten the locknut
1.
ENGINE IDLE SPEED
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
Inspect initially at 1 month and every 3 months there-
after.
Inspect initially at 1 month and every 3 months there-
after.
PartShark.com
877-999-5686
2-10 PERIODIC MAINTENANCE
ENGINE OIL AND OIL FILTER
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.
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.
Replace initially at 1 month and every 6 months there-
after.
PartShark.com
877-999-5686
PERIODIC MAINTENANCE 2-11
Apply engine oil lightly to new O-rings
A and
B before install-
ing 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)
"
FINAL GEAR OIL
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 0C or 32F.
Remove the final gear case under cover
1 by removing three
bolts.
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.
Inspect every 6 months.
Replace every 2 years.
PartShark.com
877-999-5686
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.
%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
Remove the spark arrester bolt
1.
Extract the spark arrester
2 from the muffler.
Clean the spark arrester
2 with a brush.
'
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)
Clean every 6 months.
Only clean the spark arrester in an open area away
from combustible materials. Exhausted hot carbon
particles can start a fire.
PartShark.com
877-999-5686
PERIODIC MAINTENANCE 2-13
CLUTCH
Remove the clutch adjuster cap
1.
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)
Adjust every 6 months.
PartShark.com
877-999-5686
2-14 PERIODIC MAINTENANCE
BRAKES
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)
"
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).
Inspect initially at 1 month and every 3 months there-
after.
Replace the brake pads as a set, otherwise braking
performance will be adversely affected.
PartShark.com
877-999-5686
PERIODIC MAINTENANCE 2-15
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 )
BRAKE FLUID
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, replen-
ish with brake fluid that meets the following specification.
(Specification and classification: DOT 4
'
Inspect every 3 months.
Replace every 2 years.
* The brake system of this vehicle is filled with a gly-
col-based brake fluid. Do not use or mix different
types of fluid such as silicone-based and petro-
leum-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.
PartShark.com
877-999-5686
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 cyl-
inder and thus interferes with the full braking performance of the
brake caliper. The presence of air is indicated by sponginess
of the brake lever and also by lack of braking force. Considering
the danger to which such trapped air exposes the machine and
rider, it is essential that after remounting the brake and restoring
the brake system to the normal condition, the brake fluid circuit
be purged of air in the following manner:
Fill the 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 chemi-
cally with paint, plastics, rubber materials, etc.
PartShark.com
877-999-5686
PERIODIC MAINTENANCE 2-17
BRAKE HOSE
Check the brake hoses for leakage, cracks, wear and dam-
age. If any damages are found, replace the brake hoses with
new ones.
TIRES
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
Inspect every 6 months.
Replace every 4 years.
Inspect every 3 months.
4.0 mm
(0.16 in)
PartShark.com
877-999-5686
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, main-
tain the correct tire pressure for good roadability and a longer
tire life. Cold inflation tire pressure is as follows.
VEHICLE LOAD CAPACITY LIMIT: 110 kg (243 lbs)
"
"
COLD INFLATION TIRE PRESSURE kPa
kgf/cm
2
psi
FRONT 30 0.30 4.4
REAR 25 0.25 3.6
To minimize the possibility of tire damage from
over-inflation, we strongly recommended that a man-
ual type air pump be used rather than a high pressure
air compressor as found in service stations. When fill-
ing 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 speci-
fied tires.
PartShark.com
877-999-5686
PERIODIC MAINTENANCE 2-19
STEERING
Steering system should be adjusted properly for smooth han-
dling of the handlebars and safe running.
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)
SUSPENSIONS
Inspect the suspension arms and bushings for scratches,
wear or damage. If any damages are found, replace the sus-
pension 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)
Inspect initially at 1 month and every 3 months there-
after.
Forward
Inspect every 6 months.
PartShark.com
877-999-5686
2-20 PERIODIC MAINTENANCE
CHASSIS BOLTS AND NUTS
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.)
Tighten initially at 1 month and every 3 months there-
after.
Item N•m kgf-m lb-ft
1 Handlebar clamp bolt 23 2.3 16.5
2 Steering shaft holder bolt 23 2.3 16.5
3 Steering shaft nut 49 4.9 35.5
4 Wishbone arm pivot bolt/nut (Upper and lower) 65 6.5 47.0
5 Wheel hub nut (Front) 65 6.5 47.0
6 Wheel hub nut (Rear) 138 13.8 99.9
7 Wheel set nut (Front and rear) 50 5.0 36.0
8 Steering knuckle nut (Upper and lower) 29 2.9 21.0
9 Front shock absorber mounting bolt/nut (Upper and
lower) 60 6.0 43.5
0 Tie rod end nut 29 2.9 21.0
A Tie rod lock nut 29 2.9 21.0
B Front brake air bleeder valve 6 0.6 4.4
C Front brake caliper mounting bolt 26 2.6 19.0
D Front brake pipe nut (Upper and lower) 16 1.6 11.6
E Front brake master cylinder mounting bolt 10 1.0 7.0
F Front brake hose union bolt (Upper and lower) 23 2.3 16.5
G Front brake disc plate mounting bolt 23 2.3 16.5
H Footrest bolt (M8) 26 2.6 19.0
I Footrest bolt (M10) 55 5.5 40.0
J Rear shock absorber mounting bolt/nut (Upper) 78 7.8 55.0
K Rear shock absorber mounting bolt/nut (Lower) 60 6.0 43.5
L Swingarm pivot bolt/nut 85 8.5 61.5
M Rear brake cam lever bolt/nut 11 1.1 8.0
N Rear brake panel mounting nut 60 6.0 43.5
O Rear brake pedal mounting bolt 11 1.1 8.0
P Rear axle housing set bolt/nut (RH) 60 6.0 43.5
Q Rear axle housing set bolt/nut (LH) 65 6.5 47.0
R Rear axle housing/final gear case bolt 65 6.5 47.0
PartShark.com
877-999-5686
PERIODIC MAINTENANCE 2-21
PartShark.com
877-999-5686
2-22 PERIODIC MAINTENANCE
PartShark.com
877-999-5686
PERIODIC MAINTENANCE 2-23
GENERAL LUBRICATION
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.
Lubricate initially at 1 month and every 3 months
thereafter.
PartShark.com
877-999-5686
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 mainte-
nance 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)
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 sec-
onds. Record the maximum gauge reading as the cylinder
compression.
$09915-64510: Compression gauge set
09918-02410: Adaptor or
09918-03810: Adaptor
PartShark.com
877-999-5686
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:
Low or high oil pressure can indicate any of the following conditions:
LOW OIL PRESSURE
* Clogged oil filter
* Oil leakage from the oil passage
* Damaged O-ring
* Defective oil pump
* Combination of the above items
HIGH OIL PRESSURE
* Engine oil viscosity is too high
* Clogged oil passage
* Combination of the above items
OIL PRESSURE TEST PROCEDURE
Connect 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 pres-
sure gauge.
$09915-74511: Oil pressure gauge
09915-74512: Oil pressure gauge adaptor
Above 30 kPa (0.3 kgf/cm†, 4.3 psi) at 3 000 r/min, oil temp. at 60 C (140 F)
Below 70kPa (0.7 kgf/cm†, 9.9 psi)
PartShark.com
877-999-5686
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 thor-
oughly check the operation of the drive train. Perform the follow-
ing:
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 maxi-
mum engine speed sustained during the test cycle.
%Lock-up speed: 3 100 3 700 r/min
"
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
Do not apply full power for more than 5 seconds or
damage to the clutch or engine may occur.
PartShark.com
877-999-5686
ENGINE 3-1
ENGINE
CONTENTS
3
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
PartShark.com
877-999-5686
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
ENGINE RIGHT SIDE
ENGINE CENTER
PARTS REMOVAL INSTALLATION
Neutral switch 3-15 3-70
Secondary driven bevel gear 3-15 3-69
Generator cover 3-15 3-69
Starter idle gear 3-15 3-69
Generator 3-19 3-63
PARTS REMOVAL INSTALLATION
Oil filter 3-16 3-69
Clutch cover 3-16 3-68
Clutch 3-16 3-65
Gearshift 3-18 3-64
Oil pump drive gear 3-18 3-64
Oil pump 3-18 3-64
PARTS REMOVAL INSTALLATION
Starter motor 3-12 3-76
Cam chain tension adjuster 3-13 3-75
Cylinder head cover 3-13 3-75
Camshaft 3-13 3-73
Cylinder head 3-14 3-72
Cylinder 3-14 3-72
Piston 3-14 3-70
Cam chain 3-20 3-63
PartShark.com
877-999-5686
ENGINE 3-3
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)
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)
PartShark.com
877-999-5686
3-4 ENGINE
Turn the fuel valve to theON position.
Disconnect the fuel and vacuum hoses.
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 cou-
pler
8.
Remove the left footrest
9.
PartShark.com
877-999-5686
ENGINE 3-5
Remove the gearshift lever link
0.
Remove the reverse lock release cable
A.
Disconnect the spark plug cap.
Remove the right footrest
B.
Remove the brake pedal
C.
PartShark.com
877-999-5686
3-6 ENGINE
Loosen the muffler connecting bolt.
Remove the exhaust pipe and gasket.
Disconnect the breather hose
D.
Remove the starter motor lead wire.
Remove the rear upper engine mounting nut, bolts and
bracket
E.
PartShark.com
877-999-5686
ENGINE 3-7
Remove the front and rear lower engine mounting nuts and
bolts.
Disengage the secondary driven gear shaft from the universal
joint.
Remove the right front fender bracket
F.
Dismount the engine to the right side.
PartShark.com
877-999-5686
3-8 ENGINE
ENGINE INSTALLATION
Remount the engine in the reverse order of engine removal.
Pay attention to the following points:
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.
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.
ITEM N•m kgf-m lb-ft
23 2.3 16.5
66 6.6 48.0
PartShark.com
877-999-5686
ENGINE 3-9
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.
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)
Engage the secondary driven gear shaft to the universal joint.
Install new gasket as its projections face outside.
Gearshift lever
PartShark.com
877-999-5686
3-10 ENGINE
Install a new exhaust pipe/muffler connector
4 into the muf-
fler lip.
NOTE:
Exhaust gas sealer should be applied to both of the inside and
outside of the connector
4.
EXHAUST GAS SEALER: PERMATEX 1372
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)
PartShark.com
877-999-5686
ENGINE 3-11
Install the reverse gearshift arm.
%Reverse gearshift arm angle
B: 20
Install the gearshift lever.
%Gearshift arm angle
C: 35
Adjust the gearshift lever height
D.
%Gearshift lever height
D
DD
D: 0  10 mm (0  0 .4 in)
Position the carburetor clamps as shown in the illustration.
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
Engine side Air cleaner side
Left Right
45ß
PartShark.com
877-999-5686
3-12 ENGINE
ENGINE DISASSEMBLY
ENGINE TOP SIDE
SPARK PLUG
Remove the spark plug.
&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.
PartShark.com
877-999-5686
ENGINE 3-13
CAM CHAIN TENSION ADJUSTER
Remove the spring holder bolt
1, pin and spring.
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.
PartShark.com
877-999-5686
3-14 ENGINE
Remove the C-ring
5.
'
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 por-
tion 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 cir-
clip into the crankcase.
Remove the cylinder gasket and dowel pins.
Do not drop the C-ring
5 into the crankcase.
PartShark.com
877-999-5686
ENGINE 3-15
ENGINE BOTTOM SIDE
NEUTRAL SWITCH
Remove the neutral switch
1.
Remove the switch contacts
2 and springs.
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.
PartShark.com
877-999-5686
3-16 ENGINE
OIL FILTER
Remove the oil filter cover.
Remove the oil filter and O-ring
1.
CLUTCH COVER
Remove the clutch cover.
Remove the dowel pins and gasket.
Remove the clutch release ball assembly
1, inner ball guide
2, washer
3 and clutch release arm
4.
CLUTCH
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
'
Remove the clutch shoes
1 and washer.
Clutch shoe nut has left-hand threads.
PartShark.com
877-999-5686
ENGINE 3-17
Remove the clutch wheel assembly
1.
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.
PartShark.com
877-999-5686
3-18 ENGINE
GEARSHIFT
Remove the gearshift arm
1.
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.
PartShark.com
877-999-5686
ENGINE 3-19
Remove the pin
2 and washer
3.
Remove the oil pump.
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.
PartShark.com
877-999-5686
3-20 ENGINE
CAM CHAIN
Remove the cam chain.
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.
PartShark.com
877-999-5686
ENGINE 3-21
DRIVE TRAIN/GEARSHIFT CAM
Remove the reverse idle gear assembly
1.
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
PartShark.com
877-999-5686
3-22 ENGINE
DRIVE BEVEL GEAR
Using a chisel, unlock the nut.
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.
PartShark.com
877-999-5686
ENGINE 3-23
ENGINE COMPONENTS INSPECTION AND SERVICE
CYLINDER HEAD COVER
DISASSEMBLY
'
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)
Be sure to identify each removed part as to its loca-
tion, and lay the parts out in groups designated as
Exhaust ,  Intake , so that each will be restored to
the original location during assembly.
PartShark.com
877-999-5686
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
REASSEMBLY
Reassemble the cylinder head cover in the reverse order of dis-
assembly. 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 cylin-
der 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 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)
Install the gasket washers to prevent oil leakage.
PartShark.com
877-999-5686
ENGINE 3-25
CYLINDER HEAD
DISASSEMBLY
Remove the intake pipe
1.
Remove the cam chain tensioner
2.
Cam chain tentioner inspection (!3-34)
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 inspect-
ing 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
PartShark.com
877-999-5686
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
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
TT
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. Mea-
sure the valve stem deflection in two directions, X and Y, per-
pendicular 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
X
Y
PartShark.com
877-999-5686
ENGINE 3-27
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)
&09900-20205: Micrometer (0  25 mm)
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.
PartShark.com
877-999-5686
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.
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 fol-
lowing specification.
%Valve seat width
W
WW
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.
&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)
'
INTAKE EXHAUST
15N-212 N-121
45N-608 N-122
The valve seat contact area must be inspected after
each cut.
Valve seat
PartShark.com
877-999-5686
ENGINE 3-29
When installing the solid pilot, rotate it slightly. Seat the pilot
snugly. Install the 45 cutter, attachment and T-handle.
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 con-
dition the seat some more.
NOTE:
Cut only the minimum amount necessary from the seat to pre-
vent 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
PartShark.com
877-999-5686
3-30 ENGINE
FINAL SEAT CUT
If the contact area
W is too low or too narrow, use the 45 cut-
ter to raise and widen the contact area.
NOTE:
After cutting the 15 angle, it is possible that the valve seat (45)
is too narrow. If so, re-cut the valve seat to the correct width.
After the desired seat position and width is achieved, use the
45 cutter very lightly to clean up any burrs caused by the pre-
vious cutting operations.
'
NOTE:
After servicing the valve seats, be sure to check the valve clear-
ance 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.
(
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)
Too low or too narrow contact surface
on the valve
Do not use lapping compound after the final cut is
made. The finished valve seat should have a velvety
smooth finish but not a highly polished or shiny fin-
ish. This will provide a soft surface for the final seat-
ing of the valve which will occur during the first few
seconds of engine operation.
Always use extreme caution when handling gasoline.
PartShark.com
877-999-5686
ENGINE 3-31
VALVE SPRING
The force of the coil spring keeps the valve seat tight. Weak-
ened spring result in reduced engine power output, and often
account for the chattering noise coming from the valve mecha-
nism.
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.
%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)
&09900-20101: Vernier calipers
REASSEMBLY
Install each valve spring seat.
Apply engine oil to each oil seal and press-fit them into posi-
tion.
'
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
'
Install the valve spring with the smaller pitch portion
A facing
the cylinder head.
A Smaller pitch portion.
B Larger pitch portion.
256  294 N
36.6 mm
Do not reuse the oil seal.
When inserting each valve into the valve guides, make
sure not to damage the lip of the oil seal.
Cylinder head
PartShark.com
877-999-5686
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
'
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)
'
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 speci-
fied torque.
"Cam chain tensioner mounting bolt:
13 N•m (1.3 kgf-m, 9.5 lb-ft)
Be sure to restore each spring, valve and spring
retainer to their original positions.
Use the new O-ring to prevent sucking air from the
joint.
PartShark.com
877-999-5686
ENGINE 3-33
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 opera-
tion 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.
%Cam height
H
HH
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 gas-
ket 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 com-
pressed plastigauge with envelope scale. This measurement
should be taken at the widest part of the compressed plasti-
gauge.
PartShark.com
877-999-5686
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 clear-
ance is incorrect.
%Camshaft journal O.D.
Standard: 21.959  21.976 mm
(0.8645  0 .8652 in)
&09900-20205: Micrometer (0  2 5 mm)
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.
PartShark.com
877-999-5686
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 read-
ing 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
CYLINDER BORE
Inspect the cylinder wall for any scratches, nicks or other dam-
age. 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 cylin-
der 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)
PartShark.com
877-999-5686
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 ser-
vice 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)
%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 cal-
ipers 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
PartShark.com
877-999-5686
ENGINE 3-37
Oversize piston ring
The following oversize piston rings are used. They bear the fol-
lowing identification numbers.
Oversize oil ring
The following oversize oil ring is available as optional parts.
They bear the following identification mark.
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)
SIZE 1st 2nd
0.5 mm O.S. 50 50
SIZE COLOR
STD NIL
0.5 mm O.S. Painted Red
0.5 mm O.S.
Oil ring spacer
Paint
PartShark.com
877-999-5686
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)
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 clear-
ance with the thickness gauge. If the clearance exceeds the ser-
vice 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)
PartShark.com
877-999-5686
ENGINE 3-39
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)
&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 cali-
pers, 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
PartShark.com
877-999-5686
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.
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.
PartShark.com
877-999-5686
ENGINE 3-41
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
Install the starter driven gear to the starter clutch.
Check that the starter driven gear turns only in counter clock-
wise.
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
PartShark.com
877-999-5686
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
Disassemble the transmission as shown.
Reverse driven gear
Reverse gear dog
1st driven gear
5th driven gear
3rd driven gear
4th driven gear
2nd driven gear
Driveshaft
Countershaft
5th drive gear
3rd drive gear
4th drive gear
2nd drive gear
Reverse idle gear
Reverse idle shaft
PartShark.com
877-999-5686
ENGINE 3-43
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.
'
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.
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.
* 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.
Thrust
Sharp edge
PartShark.com
877-999-5686
3-44 ENGINE
When installing the bushings, align the shaft hole with the
bushing hole.
PartShark.com
877-999-5686
ENGINE 3-45
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 respec-
tive gear with the thickness gauge.
If the clearance exceeds specification, replace the fork, its
respective gear, or both.
%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  0.181 in)
%Shift fork thickness
Standard: 4.30  4.40 mm (0.169  0.173 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)
PartShark.com
877-999-5686
3-46 ENGINE
CLUTCH COVER
DISASSEMBLY
Remove the clutch release outer guide
1.
Remove the bearing with the special tool.
&09921-20240: Bearing remover set
NOTE:
If there is no abnormal noise, the bearing removal is not neces-
sary.
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.
PartShark.com
877-999-5686
ENGINE 3-47
CRANKCASE
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 any-
thing unusual.
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
'
Play Play
The removed bearings should be replaced with new
ones.
PartShark.com
877-999-5686
3-48 ENGINE
BEARING INSTALLATION
Install the bearings with the special tool.
&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.
PartShark.com
877-999-5686
ENGINE 3-49
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.
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 spe-
cial tool.
&09913-70210: Bearing installer set
OIL JET INSTALLATION
Install the new oil jet in the proper direction.
Inside
PartShark.com
877-999-5686
3-50 ENGINE
CRANKSHAFT
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)
Crankshaft (R)
Crank pin
Bearing
Conrod
Crankshaft (L)
PartShark.com
877-999-5686
ENGINE 3-51
DRIVE TRAIN
SECONDARY BEVEL GEARS CONSTRUCTION
Bearing
Shim
Secondary bevel drive gear
Washer
Washer
Secondary bevel driven gear
Shim
Bearing
Secondary bevel gear shaft
Bearing
Oil seal
O-ring
Water proof cover
Snap ring
ITEM N•m kgf-m lb-ft
, 100 10.0 72.5
PartShark.com
877-999-5686
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.
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.
PartShark.com
877-999-5686
ENGINE 3-53
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.
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.
PartShark.com
877-999-5686
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)
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
PartShark.com
877-999-5686
ENGINE 3-55
SECONDARY GEAR SHIMS ADJUSTMENT
Remove the secondary bevel gear cover.
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 Shim adjustment
Under 0.03 mm
(0.001 in) Decrease shim thickness
0.03 0.15 mm
(0.001 0.006 in) Correct
Over 0.15 mm
(0.006 in) Increase shim thickness
Part No. Shim thickness
For driven bevel gear ( 3-58)
09181-25051
09181-25052
09181-25053
09181-25054
09181-25055
09181-25056
09181-25057
09181-25058
09181-25059
09181-25060
09181-25061
09181-25062
09181-25063
0.60 mm (0.0236 in)
0.65 mm (0.0256 in)
0.70 mm (0.0276 in)
0.75 mm (0.0295 in)
0.80 mm (0.0315 in)
0.85 mm (0.0335 in)
0.90 mm (0.0354 in)
0.95 mm (0.0374 in)
1.00 mm (0.0394 in)
1.05 mm (0.0413 in)
1.10 mm (0.0433 in)
1.15 mm (0.0453 in)
1.20 mm (0.0472 in)
PartShark.com
877-999-5686
3-56 ENGINE
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 machinists 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.
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.
'
Make sure to check the backlash after the tooth con-
tact 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
Drive bevel gear shim adjustment
Driven bevel gear shim adjustment
Contact at tooth top
1Increase shim thickness Increase shim thickness
Contact at tooth root
3Decrease shim thickness Decrease shim thickness
PartShark.com
877-999-5686
ENGINE 3-57
Part No. Shim thickness
For drive bevel gear ( 3-58)
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)
24935-19B00-115
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)
0.95 mm (0.0374 in)
1.00 mm (0.0394 in)
1.05 mm (0.0413 in)
1.10 mm (0.0433 in)
1.15 mm (0.0453 in)
24935-19B00-110
24935-19B00-105
24935-19B00-100
24935-19B00-095
24935-19B00-090
Combined shim
0.25+0.25=0.50 mm (0.0197 in)
0.25+0.30=0.55 mm (0.0217 in)
PartShark.com
877-999-5686
3-58 ENGINE
REASSEMBLY INFORMATION
ITEM N•m kgf-m lb-ft
100 10.0 72.5
Part No. Shim thickness
List of shims available for the drive bevel gear side
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)
24935-19B00-115
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)
0.95 mm (0.0374 in)
1.00 mm (0.0394 in)
1.05 mm (0.0413 in)
1.10 mm (0.0433 in)
1.15 mm (0.0453 in)
24935-19B00-110
24935-19B00-105
24935-19B00-100
24935-19B00-095
24935-19B00-090
Combined shim
0.25+0.25=0.50 mm (0.0197 in)
0.25+0.30=0.55 mm (0.0217 in)
Part No. Shim thickness
List of shims available for the driven bevel
gear side
09181-25051
09181-25052
09181-25053
09181-25054
09181-25055
09181-25056
09181-25057
09181-25058
09181-25059
09181-25060
09181-25061
09181-25062
09181-25063
0.60 mm (0.0236 in)
0.65 mm (0.0256 in)
0.70 mm (0.0276 in)
0.75 mm (0.0295 in)
0.80 mm (0.0315 in)
0.85 mm (0.0335 in)
0.90 mm (0.0354 in)
0.95 mm (0.0374 in)
1.00 mm (0.0394 in)
1.05 mm (0.0413 in)
1.10 mm (0.0433 in)
1.15 mm (0.0453 in)
1.20 mm (0.0472 in)
PartShark.com
877-999-5686
ENGINE 3-59
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 reas-
sembling.
ENGINE BOTTOM SIDE
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.
PartShark.com
877-999-5686
3-60 ENGINE
CRANKSHAFT
When mounting the crankshaft in the crankcase, it is neces-
sary to pull its left end into the crankcase with the special tool.
NOTE:
Use proper bars.
&09910-32812: Crankshaft installer
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.
PartShark.com
877-999-5686
ENGINE 3-61
Install the gearshift cam.
Install the gearshift forks and shafts as shown.
NOTE:
Each fork differs in shape.
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.
PartShark.com
877-999-5686
3-62 ENGINE
Install the oil sump filter as its projection
A faces upward.
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 crank-
case.
,99104-31140: SUZUKI BOND 1207B (USA)
-99000-31110: SUZUKI BOND 1215 (Others)
PartShark.com
877-999-5686
ENGINE 3-63
Assemble the crankcase within a few minutes.
NOTE:
Fit the clamp to the bolt
A.
"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 com-
pletely 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
PartShark.com
877-999-5686
3-64 ENGINE
OIL PUMP
Install the oil pump.
Install the washer
1 and pin
2.
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.
PartShark.com
877-999-5686
ENGINE 3-65
Apply THREAD LOCK to the gearshift cam bolt and install the
gearshift cam plate guide.
$99000-32050: THREAD LOCK 1342
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.
Gray (Paper)
Black (Cork)
PartShark.com
877-999-5686
3-66 ENGINE
Install the clutch pressure plate
2.
Align the clutch drive plates in line to facilitate later assembly.
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
Washer
OUTSIDE
PartShark.com
877-999-5686
ENGINE 3-67
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
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.
PartShark.com
877-999-5686
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.
While holding the generator rotor with the special tool, tighten
the clutch shoe nut to the specified torque.
&09930-44520: Generator rotor holder
'
"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.
INSIDE
Washer
OUTSIDE
The clutch shoe nut has left-hand threads.
PartShark.com
877-999-5686
ENGINE 3-69
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.
'
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.
Use new O-rings to prevent oil leakage.
PartShark.com
877-999-5686
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)
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.
'
When installing the spacer, be careful not to allow its
two ends to overlap in the groove.
INCORRECT
CORRECT
PartShark.com
877-999-5686
ENGINE 3-71
Install the 2nd ring
3 and the 1st ring
4.
NOTE:
1st ring and 2nd ring differ in shape.
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.
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.
'
1st ring
EX
IN
 2nd ring
 Lower side
rail
 Upper side
rail
 1st ring
 Spacer
Use new piston pin circlips to prevent circlip failure
with bent ones.
PartShark.com
877-999-5686
3-72 ENGINE
CYLINDER
Fit the dowel pins and new gasket
1.
'
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.
!
'
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 a new gasket to prevent gas leakage.
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.
Use new gasket to prevent gas leakage.
PartShark.com
877-999-5686
ENGINE 3-73
Install the cylinder head.
Install the washers and cylinder head nuts (M8) as shown.
Tighten the cylinder head nuts (M8) diagonally to the speci-
fied 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.
'
NOTE:
Before installing the camshaft to the cylinder head, apply engine
oil to the camshaft journals and cam faces.
IN.
EX.
Pull the cam chain upward, or the chain will be caught
between crankcase and cam drive sprocket.
PartShark.com
877-999-5686
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.
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
PartShark.com
877-999-5686
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
99000-31230: SUZUKI BOND 1216B
Apply SUZUKI BOND to the mating surface of the cylinder
head cover.
99000-31230: SUZUKI BOND 1216B
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)
'
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.
1216
1216
1216
1216
Fit the washer to the bolt
A.
PartShark.com
877-999-5686
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.
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 mount-
ing 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)
PartShark.com
877-999-5686
2
4
6
DRIVE TRAIN 4-1
CONTENTS
DRIVE TRAIN
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
PartShark.com
877-999-5686
4-2 DRIVE TRAIN
REAR DRIVING SYSTEM
Final gear case cover
Shim, LH
Bevel ring gear
Shim, RH
Final gear case
Shim
Bevel pinion gear
Pinion gear shaft coupling joint
Propeller shaft
Universal joint
FWD
PartShark.com
877-999-5686
DRIVE TRAIN 4-3
REAR DRIVE REMOVAL
Remove the final gear case under cover
1.
Drain gear oil. (!2-11)
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.
PartShark.com
877-999-5686
4-4 DRIVE TRAIN
Remove the rear axle together with the axle housing.
Remove the O-ring
4.
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.
PartShark.com
877-999-5686
DRIVE TRAIN 4-5
Remove the snap ring.
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 nec-
essary.
#
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.
#
Remove the oil seal with a suitable tool.
NOTE:
If there is no abnormal condition, the oil seal removal is not nec-
essary.
#
The removed bearing must be replaced with a new
one.
The removed bearing and oil seal must be replaced
with the new ones.
The removed oil seal must be replaced with a new one.
PartShark.com
877-999-5686
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 nec-
essary.
#
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 nec-
essary.
#
Unstake the bearing locknut with a small chisel or drill.
Remove the bearing locknut with the special tool.
"09921-21820: Bearing locknut wrench
#
The removed bearing must be replaced with a new
one.
The removed oil seal must be replaced with a new one.
Replace the bearing locknut with a new one.
PartShark.com
877-999-5686
DRIVE TRAIN 4-7
Remove the pinion gear assembly and shim.
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 nec-
essary.
#
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 nec-
essary.
#
The removed O-ring and bearing must be replaced
with the new ones.
The removed bearing must be replaced with a new
one.
PartShark.com
877-999-5686
4-8 DRIVE TRAIN
UNIVERSAL JOINT
Remove the C-rings from the universal joint.
#
Remove the bearings by tapping with the special tool and a
hammer.
"09913-70210: Bearing installer set
Remove the universal joint.
Replace the removed C-rings with new ones.
PartShark.com
877-999-5686
DRIVE TRAIN 4-9
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.
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
PartShark.com
877-999-5686
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
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 dam-
age.
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.
PartShark.com
877-999-5686
DRIVE TRAIN 4-11
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 sol-
vent.
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)
PartShark.com
877-999-5686
4-12 DRIVE TRAIN
FINAL GEAR CASE BEARING
Drive the bearings into the gear case and case cover with the
special tool.
"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)
PartShark.com
877-999-5686
DRIVE TRAIN 4-13
BEVEL PINION GEAR SHAFT BEARING
Drive the bearing onto the shaft with the special tool.
"09913-70210: Bearing installer set
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.
PartShark.com
877-999-5686
4-14 DRIVE TRAIN
BEVEL PINION GEAR SHAFT OIL SEAL
Install new stopper ring to pinion gear shaft securely.
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.
PartShark.com
877-999-5686
DRIVE TRAIN 4-15
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)
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
PartShark.com
877-999-5686
4-16 DRIVE TRAIN
Install new C-rings by tapping with a copper hammer.
After reassembling the universal joint, check the joint move-
ment 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 atten-
tion 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)
PartShark.com
877-999-5686
DRIVE TRAIN 4-17
Install the spring into the rear end of the propeller shaft.
Apply SUZUKI SUPER GREASE to the splines of the propel-
ler shaft.
$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)
PartShark.com
877-999-5686
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)
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 cor-
rect. 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.
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.
Backlash Shim adjustment
Under 0.05 mm
(0.0020 in) Increase shim thickness
0.05  0.30 mm
(0.0020  0 .0118 in) Correct
Over 0.30 mm
(0.0118 in) Decrease shim thickness
1.26 mm (0.0496 in)
1.32 mm (0.0520 in)
1.38 mm (0.0543 in)
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)
Part No. Shim thickness
For right side of ring gear ( 4-21)
27407-05820
(Shim set: 10 pcs)
PartShark.com
877-999-5686
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)
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. 1.26 mm (0.0496 in)
1.32 mm (0.0520 in)
1.38 mm (0.0543 in)
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)
Part No. Shim thickness
For left side of ring gear ( 4-21)
27407-05820
(Shim set: 10 pcs)
PartShark.com
877-999-5686
4-20 DRIVE TRAIN
TOOTH CONTACT
After backlash adjustment and left shim selection are carried
out, the tooth contact must be checked. Pay attention to the fol-
lowing 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 O-
ring.
Rotate the gear several turns in each direction. This will pro-
vide 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.
#
Tooth contact Shim adjustment
Contact at tooth top
1Decrease shim thickness
Contact at tooth root
3Increase shim thickness
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.
(Contact at tooth top)
(Contact at tooth root)
Correct
Incorrect
Incorrect
Part No. Shim thickness
For pinion gear ( 4-21)
1.38 mm (0.0543 in)
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)
27407-05810
(Shim set: 6 pcs)
PartShark.com
877-999-5686
DRIVE TRAIN 4-21
REASSEMBLY INFORMATION
Pinion gear shim
Right side of
ring gear shim
Matching surfaces
26 N•m
(2.6 kgf-m, 19.0 lb-ft)
26 N•m
(2.6 kgf-m, 19.0 lb-ft)
Left side of
ring gear shim
4  5 g ram
100 N.m
(10.0 kgf-m, 72.5 lb-ft)
PartShark.com
877-999-5686
4-22 DRIVE TRAIN
4  5 g ram
PartShark.com
877-999-5686
FUEL SYSTEM 5-1
5
FUEL SYSTEM
CONTENTS
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
PartShark.com
877-999-5686
5-2 FUEL SYSTEM
FUEL TANK
CONSTRUCTION
Fuel tank
Fuel cap
Breather hose
Gasket
Seal washer
Fuel valve
Fuel hose
PartShark.com
877-999-5686
FUEL SYSTEM 5-3
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 dam-
ages 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.
"
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.
Gasoline is highly flammable and explosive. Keep
heat, sparks and flames away from gasoline.
PartShark.com
877-999-5686
5-4 FUEL SYSTEM
FUEL VALVE
REMOVAL AND INSPECTION
Remove the fuel tank. (!5-3)
Drain fuel completely.
Remove the fuel valve.
"
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.
"
Gasoline is highly flammable and explosive. Keep
heat, sparks and flames away from gasoline.
Replace the removed gasket
1 and seal washers
2
with the new ones to prevent leakage of fuel.
PartShark.com
877-999-5686
FUEL SYSTEM 5-5
CARBURETOR
CONSTRUCTION
Top cap
Spring
Holder
O-ring
Spring
Washer (t=0.5 mm, 0.02 in)
E-ring
Spacer
Washer (t=1.0 mm, 0.04 in)
Jet needle
Diaphragm
Ring
Piston valve
Vacuum hose
Air vent hose
Side cover
O-ring
Coasting enrichment valve
Coasting enrichment valve cover
Starter plunger
Pilot air jet
Pilot jet
Needle valve
Needle jet
O-ring
Starter jet
Needle jet holder
Main jet ring
Main jet
Float
O-ring
Washer
Spring
Pilot screw
Throttle stop screw
O-ring
Float chamber
PartShark.com
877-999-5686
5-6 FUEL SYSTEM
SPECIFICATIONS
E-19: EU E-28: Canada E-33: USA (California)
I.D. NO. LOCATION
Carburetor has an I.D. number
1 printed on its body.
ITEM SPECIFICATION
E-19, 28 E-33
Carburetor type MIKUNI BSR29 ←
Bore size 29.0 mm
(1.14 in) ←
I.D. No. 21G0 21G1
Idle r/min 1 500 – 100 r/min ←
Float height 13.0 – 1.0 mm
(0.51 – 0.04 in) ←
Main jet (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 PRE-SET
Throttle cable play 3  5 mm
(0.12  0.20 in) ←
Starter (enricher) plunger cable play 0.5  1 .0 mm
(0.02  0.04 in) ←
PartShark.com
877-999-5686
FUEL SYSTEM 5-7
REMOVAL
Remove the seat. (!7-5)
Disconnect the air vent hose
1.
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.
PartShark.com
877-999-5686
5-8 FUEL SYSTEM
DISASSEMBLY
Remove the fuel hose
1, overflow hose
2, vacuum hose
3
and air vent hose
4.
Remove the throttle stop screw
5.
Remove the carburetor top cap.
#
Remove the spring and diaphragm assembly
6.
Remove the jet needle holder.
Do not use compressed air on the carburetor body
before removing the diaphragm; this may damage the
diaphragm.
PartShark.com
877-999-5686
FUEL SYSTEM 5-9
Remove the following parts.
7 Jet needle holder
8 O-ring
9 Spring
0 Washer (t=0.5 mm, 0.02 in)
A Jet needle
B Washer (t=1.0 mm, 0.04 in)
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.
PartShark.com
877-999-5686
5-10 FUEL SYSTEM
Remove the float chamber.
Remove the O-ring
G.
#
Remove the float pin
H, float
I and needle valve
J.
Remove the valve seat
K.
Replace the removed O-ring with a new one to prevent
leakage of fuel.
PartShark.com
877-999-5686
FUEL SYSTEM 5-11
Remove the following parts.
LMain jet, main jet ring, needle jet holder and needle jet
MPilot screw
NStarter jet
OPilot jet
NOTE:
Before removing the pilot screw
M, its setting must be deter-
mined. Slowly turn the pilot screw clockwise and count the num-
ber 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.
#
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 O-
ring.
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.
1Drill-stop
2Plug
3Pilot screw
4Carburetor body
Do not use wire to clean the passageways, valve seat
and jets. Use compressed air only.
PartShark.com
877-999-5686
5-12 FUEL SYSTEM
CLEANING
"
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 cir-
cuit in a dip-type cleaning solution to loosen dirt and varnish.
Dry the carburetor body using compressed air.
#
After cleaning, reassemble the carburetor.
#
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
Some carburetor cleaning chemicals, especially dip-
type soaking solutions, are very corrosive and must
be handled carefully. Always follow the chemical man-
ufacturers instructions on proper use, handling and
storage.
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 compo-
nents.
Replace the removed O-rings with new ones.
PartShark.com
877-999-5686
FUEL SYSTEM 5-13
NEEDLE VALVE INSPECTION
If foreign matter is caught between the valve seat and the nee-
dle 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 com-
pressed 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
AA
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
#
NEEDLE JET
Install the needle jet with its smaller internal diameter portion
facing to the needle jet holder.
Replace the removed O-ring with a new one.
PartShark.com
877-999-5686
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.
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 dia-
phragm is aligned with the concave section of the carburetor
bodys rim.
THROTTLE STOP SCREW
Apply SUZUKI SUPER GREASE to thread part of the throttle
stop screw, then install the throttle stop screw to the carbure-
tor.
&99000-25030: SUZUKI SUPER GREASE A  ( USA)
99000-25010: SUZUKI SUPER GREASE  A (Others)
PartShark.com
877-999-5686
FUEL SYSTEM 5-15
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.
Position the carburetor clamps as shown in the illustration.
Connect the carburetor hoses properly. (!9-16)
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
Engine side Air cleaner side
Left Right
45ß
PartShark.com
877-999-5686
PartShark.com
877-999-5686
6
LUBRICATION SYSTEM 6-1
CONTENTS
LUBRICATION SYSTEM
LUBRICATION SYSTEM ...............................................................................6- 2
ENGINE LUBRICATION CIRCUIT .........................................................6- 2
ENGINE LUBRICATION FLOW CHART ...............................................6- 4
OIL PRESSURE .............................................................................................6- 5
OIL FILTER ....................................................................................................6- 5
OIL STRAINER ..............................................................................................6- 5
OIL PUMP ......................................................................................................6- 5
PartShark.com
877-999-5686
6-2 LUBRICATION SYSTEM
LUBRICATION SYSTEM
ENGINE LUBRICATION CIRCUIT
OIL PUMP
OIL FILTER
LUBRICATION OIL
RETURNED OIL
PartShark.com
877-999-5686
LUBRICATION SYSTEM 6-3
INTAKE SIDE
LUBRICATION OIL
RETURNED OIL
EXHAUST SIDE
PartShark.com
877-999-5686
6-4 LUBRICATION SYSTEM
ENGINE LUBRICATION FLOW CHART
OIL SUMP
FILTER
ORIFICE
ORIFICE
OIL FILTER
OIL PUMP
CYLINDER
DRIVESHAFT
RIGHT END
BEARING
CLUTCH
RELEASE
BEARING
CRANKSHAFT
RIGHT END
BEARING
DRIVESHAFT
BUSHINGS/
GEARS
CONROD
BIG END
BEARING
CYLINDER
WALL &
PISTON
ROCKER
ARMS &
SHAFTS
CAMSHAFT
JOURNAL (L)
CAMSHAFT
JOURNAL (R)
CAM FACE
(IN & EX)
CAM DRIVE
CHAIN
CLUTCH
PLATES
CLUTCH
SHOE
ONE-WAY
CLUTCH
CONROD
SMALL END
CLUTCH COVER
CRANKSHAFT(R)
COUNTERSHAFT
LEFT END
BEARING
COUNTERSHAFT
BUSHINGS/GEARS
REVERSE IDLE
SHAFT
CLUTCH
SHOE
HOUSING
BUSHING
PRIMARY
DRIVEN GEAR
BUSHING
OIL JET
PartShark.com
877-999-5686
LUBRICATION SYSTEM 6-5
OIL PRESSURE
(!2-25)
OIL FILTER
(!2-10)
OIL STRAINER
(!3-20, -61 and -62)
OIL PUMP
(!3-18 and -64)
PartShark.com
877-999-5686
PartShark.com
877-999-5686
CHASSIS 7-1
CHASSIS
7
CONTENTS
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
PartShark.com
877-999-5686
7-2 CHASSIS
CHASSIS
CONTENTS
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
PartShark.com
877-999-5686
CHASSIS 7-3
EXTERIOR PARTS
CONSTRUCTION
Front fender
Fuel tank top cover
Fuel tank side cover
Front fender bracket
Headlight case
PartShark.com
877-999-5686
7-4 CHASSIS
Rear fender
Rear fender cover
Footrest
mud guard
PartShark.com
877-999-5686
CHASSIS 7-5
REMOVAL
SEAT
Remove the seat by pulling the lever.
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.
PartShark.com
877-999-5686
7-6 CHASSIS
FRONT FENDER
Remove the fuel tank side covers. (!7-5)
Remove the screws and fasteners.
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.
PartShark.com
877-999-5686
CHASSIS 7-7
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.
PartShark.com
877-999-5686
7-8 CHASSIS
Remove the screws.
Pull out the taillight assembly
2 with the bracket.
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)
PartShark.com
877-999-5686
CHASSIS 7-9
FOOTREST
Apply THREAD LOCK to the bolts
A and tighten each bolt to
the specified torque.
#99000-32050: THREAD LOCK  1342
"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)
PartShark.com
877-999-5686
7-10 CHASSIS
FRONT AND REAR WHEELS
CONSTRUCTION
Front brake disc
Spacer
Dust seal
Bearing
Spacer
Front wheel Hub
Rear wheel Hub
Hub plate
Disc cover
ITEM N•m kgf-m lb-ft
23 2.3 16.5
50 5.0 36.0
65 6.5 47.0
138 13.8 99.9
PartShark.com
877-999-5686
CHASSIS 7-11
REMOVAL
FRONT AND REAR WHEELS
Place the vehicle on the level ground.
Support the vehicle with a jack or wooden block.
Remove the wheel.
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.
$
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.
Do not operate the front brake lever while the caliper
is removed.
PartShark.com
877-999-5686
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.
Remove the dust seals with the special tool.
%09913-50121: Oil seal remover
$
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
$
Replace the removed dust seals with new ones.
Never reuse the removed bearings.
PartShark.com
877-999-5686
CHASSIS 7-13
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
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)
PartShark.com
877-999-5686
7-14 CHASSIS
Install the spacer
4 to the front wheel hub.
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)
$
REAR WHEEL HUB
Apply small amount of SUZUKI SUPER GREASE to the left
rear wheel hubs 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.
$
Replace the removed cotter pin with a new one.
Do not apply grease to the right rear wheel hubs
spline.
PartShark.com
877-999-5686
CHASSIS 7-15
Install the rear wheel hub and washer.
NOTE:
The convex side of the washer faces outside.
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)
$
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.
INSIDE
Washer
OUTSIDE
Replace the removed cotter pin with a new one.
PartShark.com
877-999-5686
7-16 CHASSIS
TIRES
TIRE REPLACEMENT
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.
$
Apply tire lubricant to the tire bead and the flange of the rim.
$
$
Mount the tire on the rim.
NOTE:
Inspect the sealing portion of the rim for contamination and dis-
tortion before installing the tire on the rim.
When using the tire lever, do not scratch or hit the
sealing portion (hump) of the wheel or it may cause
air-leakage.
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 speci-
fied tire.
PartShark.com
877-999-5686
CHASSIS 7-17
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.
Inflate the tire to seat the tire bead.
'Maximum tire bead seat pressure
Front and rear: 250 kPa (2.5 kgf/cm2, 36 psi)
$
NOTE:
Check therim 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 com-
pletely, 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)
$
'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)
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.
Before inflating the tire, check the MAXIMUM OPER-
ATING 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.
PartShark.com
877-999-5686
7-18 CHASSIS
FRONT BRAKE
CONSTRUCTION
(
$
* 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.
Master cylinder reservior cap
Diaphragm
Master cylinder clamp
Boot
Piston/cup set
Cup
Spring
Master cylinder
Brake hose No. 1
Piston
Piston seal
Dust seal
Brake caliper
Brake caliper holder
Brake pad
Pad spring
Disc cover
Front brake disc
Brake pipe
Brake hose No. 2
Master cylinder mounting bolt
Brake hose union bolt
Air bleeder valve
Brake caliper mounting bolt
Brake pad mounting pin
Caliper holder pin
Caliper holder slide pin
Brake disc bolt
Brake pipe nut
ITEM N•m kgf-m lb-ft
10 1.0 7.0
23 2.3 16.5
6 0.6 4.4
26 2.6 19.0
18 1.8 13.0
18 1.8 13.0
23 2.3 16.5
23 2.3 16.5
16 1.6 11.6
13
Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials
etc. and will damage them severely.
PartShark.com
877-999-5686
CHASSIS 7-19
BRAKE PAD REPLACEMENT
Remove the front wheel. (!7-11)
Remove the brake caliper mounting bolts
1 and brake pad
mounting pins
2.
Remove the brake pads.
$
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
* 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.
PartShark.com
877-999-5686
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)
$
BRAKE CALIPER REMOVAL AND
DISASSEMBLY
Remove the front wheel. (!7-11)
Disconnect the brake hose from the brake caliper by remov-
ing 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)
(
Remove the spring
3.
* Never reuse the brake fluid left over from previous
servicing and which has been stored for long peri-
ods of time.
* Bleed air from the brake system.
(!2-16)
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.
PartShark.com
877-999-5686
CHASSIS 7-21
Place a rag over the brake caliper piston to prevent the piston
from popping out and then force out the piston using com-
pressed air.
$
Remove the dust seal and piston seal.
$
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 cal-
iper with a new one.
Do not use high pressure air to prevent brake caliper
piston damage.
Do not reuse the dust seal and piston seal to prevent
fluid leakage.
PartShark.com
877-999-5686
7-22 CHASSIS
BRAKE CALIPER PISTON
Inspect the brake caliper piston for any scratches or other dam-
age. If any damages are found, replace the piston with a new
one.
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 dam-
ages are found, replace them with new ones.
PartShark.com
877-999-5686
CHASSIS 7-23
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
$
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
* Wash the brake caliper components with new brake
fluid before reassembly.
* Do not wipe the brake fluid off with a rag after wash-
ing 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.
PartShark.com
877-999-5686
7-24 CHASSIS
Apply SUZUKI SILICONE GREASE to the brake caliper
holder slide pin.
*99000-25100: SUZUKI SILICONE GREASE
Install the pin
1, washer
2 and caliper holder
3 to the cali-
per.
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 mount-
ing 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 pis-
tons all the way into the caliper.
$
BRAKE DISC REMOVAL AND
DISASSEMBLY
Remove the front wheel hub. (!7-11)
Remove the brake disc.
Bleed air from the system after reassembling the
brake caliper. (!2-16)
PartShark.com
877-999-5686
CHASSIS 7-25
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)
'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)
PartShark.com
877-999-5686
7-26 CHASSIS
MASTER CYLINDER REMOVAL AND
DISASSEMBLY
Place a rag underneath the brake hose union bolt on the mas-
ter cylinder to catch any split brake fluid. Remove the brake
hose union bolt and disconnect the brake hose.
$
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.
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.
PartShark.com
877-999-5686
CHASSIS 7-27
Remove the piston/secondary cup, primary cup and spring.
7 Secondary cup
8 Piston
9 Primary cup
0 Spring
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:
$
)Specification and classification: DOT 4
* Wash the master cylinder components with new
brake fluid before reassembly.
* Do not wipe the brake fluid off with a rag after wash-
ing 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.
PartShark.com
877-999-5686
7-28 CHASSIS
Align the master cylinder holders 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)
A Master cylinder
B Master cylinder upper clamp bolt
C Handlebar
D Clearance
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)
PartShark.com
877-999-5686
CHASSIS 7-29
FRONT SUSPENSION
CONSTRUCTION
Front shock absorber
Upper wishbone arm
Bushing
Lower wishbone arm
Steering knuckle
Snap ring
Knuckle end
Shock absorber mounting upper nut
Shock absorber mounting lower nut
Wishbone arm pivot nut
Steering knuckle nut
Tie rod end nut
ITEM N•m kgf.m lb-ft
60 6.0 43.5
65 6.5 47.0
29 2.9 21.0
PartShark.com
877-999-5686
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.
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.
PartShark.com
877-999-5686
CHASSIS 7-31
Remove the front shock absorber
7.
Remove the cotter pins, knuckle nuts and washers.
Disconnect the steering knuckle
8 with a commercially avail-
able 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.
PartShark.com
877-999-5686
7-32 CHASSIS
KNUCKLE
Inspect the knuckle for damage. If any damages are found,
replace the knuckle with a new one.
KNUCKLE END
Inspect the knuckle end boots for wear or damage. If any dam-
ages 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.
PartShark.com
877-999-5686
CHASSIS 7-33
REASSEMBLY AND REMOUNTING
Reassemble and remount the front suspension in the reverse
order of removal and disassembly. Pay attention to the following
points:
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 speci-
fied torque.
"Knuckle nut: 29 N•m (2.9 kgf-m, 21.0 lb-ft)
Install new cotter pins.
$
Install the front shock absorber
1.
Replace the removed cotter pins with new ones.
PartShark.com
877-999-5686
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)
"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 speci-
fied torque.
"Tie rod end nut: 29 N•m (2.9 kgf-m, 21 lb-ft)
Install new cotter pin.
$
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
(
Replace the removed cotter pin with a new one.
Be sure to adjust the spring pre-load on the both sus-
pensions equally.
PartShark.com
877-999-5686
CHASSIS 7-35
STEERING
CONSTRUCTION
ITEM N•m kgf-m lb-ft
23 2.3 16.5
23 2.3 16.5
49 4.9 35.5
29 2.9 21.0
29 2.9 21.0
Steering head cover
Handlebars
Handlebar upper clamp
Handlebar lower clamp
Brake cable guide
Steering shaft holder
Steering shaft
Dust seal
Bushing
Dust seal
O-ring
Dust seal
Tie rod
Tie rod end
Handlebar clamp bolt
Steering shaft holder bolt
Steering shaft nut
Tie rod end nut
Tie rod locknut
PartShark.com
877-999-5686
7-36 CHASSIS
REMOVAL
Remove the front fender. (!7-6)
Remove the master cylinder assembly
1 from the handle-
bars. (!7-26)
Remove the throttle lever case
2.
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.
PartShark.com
877-999-5686
CHASSIS 7-37
Remove the tie rod ends with a commercially available ball
bearing joint remover.
Remove the cotter pin and steering shaft nut
9, washer
0
and dust seal
A.
$
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.
Replace the removed cotter pins with new ones.
PartShark.com
877-999-5686
7-38 CHASSIS
Remove the steering shaft.
Remove the dust seal
F from the steering shaft.
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
Inspect the tie rod for distortion or damage. If any damages are
found, replace the tie rod with a new one.
1 Tie rod end
2 Locknut
3 Locknut
4 Tie rod
$
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.
The locknuts
2 with a yellow finished surface have
left-hand threads.
PartShark.com
877-999-5686
CHASSIS 7-39
STEERING SHAFT
Inspect the steering shaft for distortion or bends. If any damages
are found, replace the steering shaft with a new one.
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
PartShark.com
877-999-5686
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)
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.
$
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)
$
Replace the removed cotter pin with a new one.
To prevent the entry of dirt, the dust seal end
A must
face forward when installed to the steering shaft.
PartShark.com
877-999-5686
CHASSIS 7-41
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 rout-
ing are properly. (!9-12 to -14)
Degrease the tapered portions of the tie rod ends with non-
flammable 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.
$
NOTE:
When installing the tie rod, make sure the narrow end
1 of the
tie rod comes out.
$
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 mat-
ing 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)
Replace the removed cotter pins with new ones.
The locknuts
2 with a yellow finished surface have
left-hand threads.
Forward
PartShark.com
877-999-5686
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.
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.
PartShark.com
877-999-5686
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.
$
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)
The locknuts
2 have left-hand threads.
Forward
Right angle
(90 deg.)
Forward
PartShark.com
877-999-5686
7-44 CHASSIS
FRONT WHEEL, FRONT BRAKE, FRONT SUSPENSION AND
STEERING REASSEMBLING INFORMATION
ITEM N•m kgf-m lb-ft
23 2.3 16.5
49 4.9 35.5
29 2.9 21.0
60 6.0 43.5
ITEM N•m kgf-m lb-ft
60 6.0 43.5
65 6.5 47.0
29 2.9 21.0
50 5.0 36.0
65 6.5 47.0
23 2.3 16.5
Bend the cotter pin
securely.
/
PartShark.com
877-999-5686
CHASSIS 7-45
REAR BRAKE
CONSTRUCTION
ITEM N•m kgf-m lb-ft
60 6.0 43.5
11 1.1 8.0
11 1.1 8.0
Dust seal Brake camshaft Brake panel nut
Drum cover O-ring Brake cam lever nut
Brake drum Brake lining indicator plate
Brake shoe O-ring
O-ring Brake panel
Snap ring Brake cam lever
Bearing
PartShark.com
877-999-5686
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.
Remove the drum cover bolts.
Remove the drum cover
1 with a flat head screwdriver.
$
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 remov-
ing the brake shoes.
* Be careful not to distort the drum cover.
* Distortion of drum cover would cause a malfunction
of sealing.
PartShark.com
877-999-5686
CHASSIS 7-47
Disconnect the brake breather hose.
Remove the brake panel and panel cover
6.
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.
PartShark.com
877-999-5686
7-48 CHASSIS
INSPECTION
BRAKE DRUM
Measure the brake drums 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)
BRAKE SHOE
Inspect the brake shoes for wear or damage. If any wear or
damages are found, replace the brake shoes with new ones.
$
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.
$
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.
Replace the brake shoes as a set, otherwise braking
performance will be adversely affected.
Replace the removed dust seal with a new one.
PartShark.com
877-999-5686
CHASSIS 7-49
Remove the bearing with the special tool.
%09921-20240: Bearing remover set
$
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
The removed bearing must be replaced with a new
one.
Drum cover Dust seal
PartShark.com
877-999-5686
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)
$
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-rings should be replaced with new ones.
O-ring must be replaced with a new one.
PartShark.com
877-999-5686
CHASSIS 7-51
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.
Install new O-ring to the brake panel.
$
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)
(
Install the brake shoes and springs to the brake panel.
$
NOTE:
* When reinstalling the removed brake shoes, install them in
their original position, leading and trailing.
* Make sure that the brake shoe springs end faces the brake
panel as shown.
Replace the removed O-ring with a new one.
Be careful not to apply too much grease to the brake
camshaft and pin. If grease gets on the lining, brake
slippage will result.
Replace the brake shoes as a set, otherwise braking
performance will be adversely affected.
PartShark.com
877-999-5686
7-52 CHASSIS
Install the brake drum.
$
NOTE:
Before installing the brake drum, make sure that the brake drum
is clean and free of any greasey matter.
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
Do not apply grease to the spline portion of brake
drum.
PartShark.com
877-999-5686
CHASSIS 7-53
REAR SHOCK ABSORBER
CONSTRUCTION
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.
$
78 N•m (7.8 kgf-m, 55 lb-ft)
60 N•m (6.0 kgf-m, 43.0 lb-ft)
Do not attempt to disassemble the rear shock
absorber and to bleed out the nitorogen gas. It is
unserviceble.
PartShark.com
877-999-5686
7-54 CHASSIS
REAR SHOCK ABSORBER SPACER AND BEARING
Remove the spacers and dust seals.
$
Inspect the spacers for any flaws or other damage. If any dam-
ages are found, replace the spacers with new ones.
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
$
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)
The removed dust seals must be replaced with new
ones.
The removed bearing must be replaced with a new
one.
PartShark.com
877-999-5686
CHASSIS 7-55
SUSPENSION SETTING
SPRING PRE-LOAD ADJUSTMENT
The rear suspension spring pre-load is adjustable. This adjust-
ment is performed by changing spring set length.
Loosen the locknut
1.
Adjust the spring set length by turning the adjuster
2.
SPRING SET LENGTH
A
$
Tighten the locknut
1.
REAR SHOCK ABSORBER DISPOSAL
(
GAS PRESSURE RELEASE
Remove the valve cap.
Press the valve with a screwdriver to bleed out the nitrogen
gas.
(
STANDARD MAXIMUM
(SOFTEST) MINIMUM
(STIFFEST)
232.5 mm
(9.15 in) 235 mm
(9.25 in) 227 mm
(8.94 in)
Do not set the spring length out of the specified range.
* 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.
* 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 perform-
ing this procedure.
PartShark.com
877-999-5686
7-56 CHASSIS
REAR SUSPENSION
CONSTRUCTION
ITEM N•m kgf-m lb-ft
78 7.8 55.0
60 6.0 43.5
85 8.5 61.5
60 6.0 43.5
65 6.5 47.0
Rear shock absorber
Swingarm
Bearing
Rear shock absorber mounting nut (Upper)
Rear shock absorber mounting nut (Lower)
Swingarm pivot nut
Axle housing mounting nut (RH)
Axle housing bolt
Axle housing mounting nut (LH)
PartShark.com
877-999-5686
CHASSIS 7-57
REMOVAL
Remove the footrest mud guards. (!7-7)
Remove the rear drive gear case assembly. (!4-3)
Remove the rear shock absorber. (!7-53)
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 swing-
arm.
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.
PartShark.com
877-999-5686
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.
Remove the swingarm pivot bearing with the special tools.
%09923-74510: Bearing remover
09930-30104: Sliding shaft
$
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 suit-
able 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 (USA)
99000-25010: SUZUKI SUPER GREASE  A (Others)
Install the spacers and dust covers to the swingarm.
The removed bearing must be replaced with a new
one.
5.0 mm (0.197 in)
5.0 mm (0.197 in)
PartShark.com
877-999-5686
CHASSIS 7-59
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)
"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)
PartShark.com
877-999-5686
7-60 CHASSIS
REAR AXLE
CONSTRUCTION
Rear axle
Rear axle housing
65 N•m (6.5 kgf-m, 47 lb-ft)
60 N•m (6.0 kgf-m, 43.5 lb-ft)
Do not apply grease
to the spline portion of the brake drum.
PartShark.com
877-999-5686
CHASSIS 7-61
REMOVAL
Remove the rear wheels. (!7-11)
Remove the rear wheel hubs. (!7-11)
Remove the rear brake. (!7-46)
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)
PartShark.com
877-999-5686
7-62 CHASSIS
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)
PartShark.com
877-999-5686
CHASSIS 7-63
REAR WHEEL, REAR BRAKE, REAR SUSPENSION, REAR SWIN-
GARM AND REAR AXLE SHAFT REASSEMBLING INFORMATION
ITEM N•m kgf-m lb-ft
85 8.5 61.5
78 7.8 56.0
60 6.0 43.5
60 6.0 43.5
50 5.0 36.0
138 13.8 96.6
11 1.1 8.0
60 6.0 43.5
65 6.5 47.0
4 mm (0.16 in)
12 mm
(0.47 in)
5 mm
(0.20 in) 5 mm
(0.20 in)
11 N•m (1.1 kgf-m, 8.0 lb-ft)
Washer installing direction
25 mm
(0.98 in)
Do not apply grease.
Bend the cotter pin securely.
Apply grease to the sliding part.
PartShark.com
877-999-5686
7-64 CHASSIS
REVERSE LOCK RELEASE CABLE
REMOVAL
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.
PartShark.com
877-999-5686
CHASSIS 7-65
Remove the screw
7 and washers
8.
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 hous-
ing.
NOTE:
* When installing the rotor, hook the spring end
C on the con-
cave portion
D of the rotor.
* Make sure that the reverse lock release cable is routed cor-
rectly.
PartShark.com
877-999-5686
7-66 CHASSIS
CABLE PLAY ADJUSTMENT
After installing the reverse lock release cable, adjust the cable
play.
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.
PartShark.com
877-999-5686
ELECTRICAL SYSTEM 8-1
8
ELECTRICAL SYSTEM
CONTENTS
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
PartShark.com
877-999-5686
8-2 ELECTRICAL SYSTEM
CAUTIONS IN SERVICING
CONNECTORS
When disconnecting a connector, be sure to hold the termi-
nals; do not pull the lead wires.
When connecting a connector, push it in so it is firmly
attached.
Inspect the connector for corrosion, contamination and any
breakage in the cover.
COUPLERS
With a lock-type coupler, be sure to release the lock before
disconnecting it. When connecting a coupler, push it in until
the lock clicks shut.
When disconnecting a coupler, be sure to hold the coupler; do
not pull the lead wires.
Inspect each terminal on the coupler for looseness or bends.
Inspect each terminal for corrosion and contamination.
CLAMPS
Refer to the 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.
FUSES
When a fuse blows, always investigate the cause, correct the
problem, and then replace the fuse.
Do not use a fuse of a different capacity.
Do not use any 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
PartShark.com
877-999-5686
ELECTRICAL SYSTEM 8-3
BATTERY
The MF battery used in this vehicle does not require mainte-
nance (e.g., electrolyte level inspection, distilled water replen-
ishment).
During normal charging, no hydrogen gas is produced. How-
ever, if the battery is overcharged, hydrogen gas may be pro-
duced. 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 disassem-
bly 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 theWIRING
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 mea-
suring 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 instruc-
tion manual.
PartShark.com
877-999-5686
8-4 ELECTRICAL SYSTEM
LOCATION OF ELECTRICAL COMPONENTS
1CDI unit
2Battery
3Fuse
4Ignition switch
5Front brake light switch
6Rear brake light pedal switch
7Starter motor
PartShark.com
877-999-5686
ELECTRICAL SYSTEM 8-5
1 Handlebar switch (L)
7 Ignition coil
2 Rear brake light switch
8 Generator
3 Parking brake switch
9 Neutral switch
4 Neutral switch diode
0 Regulator/rectifier
5 Fuse
A Neutral relay
6 Starter relay
PartShark.com
877-999-5686
8-6 ELECTRICAL SYSTEM
CHARGING SYSTEM
TROUBLE SHOOTING
Battery runs down quickly.
Step 1
1) Check accessories which use excessive amounts of electricity.
Are accessories being installed ?
Step 2
1) Check the battery for current leaks. (!8-8)
Is the battery for current leaks OK ?
Step 3
1) Measure the regulated voltage between the battery terminals. (!8-8)
Is the battery charging of voltage OK ?
<Continued on next page>
Generator
Regulator/rectifier
Ignition switch
Fuse
Battery
Load
YES Remove accessories
NO Go to Step 2.
YES Go to Step 3.
NO Short circuit of wire harness
Faulty electrical equipment
YES Faulty battery
Abnormal driving condition
NO Go to Step 4.
PartShark.com
877-999-5686
ELECTRICAL SYSTEM 8-7
Step 4
1) Measure the resistance of the generator coil. (!8-9)
Is the resistance of generator coil OK ?
Step 5
1) Measure the generator no-load voltage. (!8-9)
Is the generator no-load voltage OK ?
Step 6
1) Inspect the regulator/rectifier. (!8-10)
Is the regulator/rectifier OK ?
Step 7
1) Inspect the wirings.
Are the wirings OK ?
Battery overcharge
Faulty regulator/rectifier
Faulty battery
Poor contact of generator lead wire coupler
YES Go to Step 5.
NO Faulty generator coil or disconnected lead wires
YES Go to Step 6.
NO Faulty generator
YES Go to Step 7.
NO Faulty regulator/rectifier
YES Faulty battery
NO Short circuit of wire harness
Poor contact of couplers
PartShark.com
877-999-5686
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
$09900-25008: Multi circuit tester set
%Tester knob indication: Current (&, 20 mA)
"
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 termi-
nals 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 fully-
charged condition.
#Regulated voltage: 14.0  15.5 V at 5 000 r/min
$09900-25008: Multi circuit tester set
(Tester knob indication: Voltage (&)
* 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. Battery
DC mA
DC V
PartShark.com
877-999-5686
ELECTRICAL SYSTEM 8-9
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
ΩΩ
Ω
(Yellow Yellow)
∞ Ω
∞ Ω∞ Ω
∞ Ω (Yellow  Ground)
$09900-25008: Multi circuit tester set
)Tester knob indication: Resistance (Ω
ΩΩ
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 gener-
ator 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 (~)
PartShark.com
877-999-5686
8-10 ELECTRICAL SYSTEM
REGULATOR/RECTIFIER
Remove the regulator/rectifier.
Measure the voltage between the terminals using the multi cir-
cuit tester, as indicated in the table below.
If the voltage is not within the specified value, replace the regu-
lator/rectifier with a new one.
$09900-25008: Multi circuit tester set
*Tester knob indication: Diode test (+)
✽ 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.
Unit: V
+ Tester probe
- Tester probe
A
B
C
D
E
F
A✽
0.5 1.2 0.4 0.7 0.4 0.7 0.4 0.7
B✽ ✽✽✽✽
C✽✽ ✽✽✽
D✽✽
0.4 0.7
✽✽
E✽✽
0.4 0.7
✽✽
F✽✽
0.4 0.7
✽✽
PartShark.com
877-999-5686
ELECTRICAL SYSTEM 8-11
STARTER SYSTEM
TROUBLE SHOOTING
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 posi-
tion.
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 ?
<Continued on next page>
Starter
motor
Fuse
Starter relay
B/W
Y/B
Neutral relay
Starter
button Engine
stop switch Ignition
switch
CDI
Neutral
indicator
light
O
B/G
Battery
Reverse
indicator
light
Neutral
switch
Bl
B/Bl
W
R/W
Parking brake switch
Bl/R
R
YES Go to Step 2.
NO Go to Step 3.
YES Faulty starter relay
Loose or disconnected starter motor lead wire
NO Faulty starter motor
PartShark.com
877-999-5686
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 ?
Step 4
1) Check the starter relay. (!8-15)
Is the starter relay OK ?
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 ?
Engine does not turn though the starter motor runs.
Faulty starter clutch. (!3-40)
YES Go to Step 4.
NO
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
YES Poor contact of the starter relay
NO Faulty starter relay
YES Open circuit in wire harness
Poor contact of connector
NO Faulty parking brake switch
PartShark.com
877-999-5686
ELECTRICAL SYSTEM 8-13
STARTER MOTOR REMOVAL AND DISAS-
SEMBLY
Remove the starter motor
1.
Disassembly the starter motor, as shown.
STARTER MOTOR INSPECTION
CARBON BRUSHES
Inspect the carbon brushes for abnormal wear, cracks, or
smoothness in the brush holder.
If any damages are found, replace the brush assembly with a
new one.
COMMUTATOR
Inspect the commutator for discoloration, abnormal wear or
undercut
A.
If abnormal wear is found, replace the armature with a new one.
If the commutator surface is discolored, polish it with #400 sand-
paper and wipe it using a clean, dry cloth.
If there is no undercut, scrape out the insulator
1 with a saw
blade.
Housing end (outside)
Brush holder
Brush spring
O-ring
Brush terminal set
Starter motor case
Washer set
Armature
Housing end (inside)
O-ring
PartShark.com
877-999-5686
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 conti-
nuity between the segments and shaft, replace the armature
with a new one.
$09900-25008: Multi circuit tester set
,Tester knob indication: Continuity test (-)
OIL SEAL
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:
"
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 arma-
ture shaft.
/99000-25140: SUZUKI MOLY PASTE
Replace the removed O-rings with new ones to pre-
vent oil leakage and moisture.
PartShark.com
877-999-5686
ELECTRICAL SYSTEM 8-15
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.
099000-32050: THREAD LOCK 1342
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.
PartShark.com
877-999-5686
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 (-)
"
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
ΩΩ
Ω
$09900-25008: Multi circuit tester set
)Tester knob indication: Resistance (Ω
ΩΩ
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)
Do not apply a battery voltage to the starter relay for
more than five seconds.
This may overheat and damage the relay coil.
PartShark.com
877-999-5686
ELECTRICAL SYSTEM 8-17
IGNITION SYSTEM
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 ?
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 ?
<Continued on next page>
YES Go to Step 2.
NO Poor connection of couplers
YES Go to Step 3.
NO
Faulty ignition switch
Faulty engine stop switch
Broken wire harness or poor connection of related circuit couplers
Spark plug
Ignition
coil
CDI unit
Ignition
switch
Fuse
Battery
Generator
Parking
brake
switch
Neutral
relay Neutral
switch
Engine
stop switch
PartShark.com
877-999-5686
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 ?
Step 4
1) Inspect the spark plug. (!2-7)
Are the spark plug OK ?
Step 5
1) Inspect the ignition coil. (!8-20)
Are the ignition coil OK ?
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 Go to Step 4.
NO Go to Step 5.
YES Poor connection of the spark plug cap
Go to Step 5.
NO Faulty spark plug
YES Go to Step 6.
NO Faulty ignition coil
YES
Faulty CDI
Open circuit in wiring harness.
Poor connection of ignition couplers
NO Faulty pickup coil
PartShark.com
877-999-5686
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.
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
"
Shift the transmission to the neutral position and turn the igni-
tion 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
If the voltage is lower than the standard values, inspect the igni-
tion coil. (!8-20)
When using the multi circuit tester and peak volt adap-
tor, refer to the appropriate instruction manual.
While testing, do not touch the tester probes and
spark plug to prevent receiving an electric shock.
Peak volt adaptor
CDI
unit
Battery
New spark plug
Ignition
coil
PartShark.com
877-999-5686
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 sec-
ondary windings using the multi circuit tester. If the resistance in
both the primary and secondary windings is close to the speci-
fied values, the windings are in sound condition.
#Ignition coil resistance
Primary : 0.05 1.0 Ω
ΩΩ
Ω (
+ Terminal
- Terminal)
Secondary : 10.5 19.0 kΩ
ΩΩ
Ω
(Spark plug cap
+ Terminal)
$09900-25008: Multi circuit tester set
)Tester knob indication: Resistance (Ω
ΩΩ
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.
Pickup coil:
+ Probe...Green/White lead wire
- Probe...Black/Yellow lead wire
$09900-25008: Multi circuit tester set
"
When using the multi circuit tester and peak volt adap-
tor, refer to the appropriate instruction manual.
Generator
Pickup coil
B/Y
G/W
G/W
B/Y
Generator
coupler
Wiring
harness
coupler
Peak volt adaptor
PartShark.com
877-999-5686
ELECTRICAL SYSTEM 8-21
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 (&)
If the peak voltage measured on the CDI unit coupler is lower
than the standard value, measure the peak voltage on the gen-
erator 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
(Tester knob indication: Voltage (&)
If the peak voltage on the generator coupler is within the specifi-
cation, 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
ΩΩ
Ω (B/Y G/W)
$09900-25008: Multi circuit tester set
(Tester knob indication: Resistance (Ω
ΩΩ
Ω)
B/Y
G/W
Generator
Pickup coil
Peak volt adaptor
PartShark.com
877-999-5686
8-22 ELECTRICAL SYSTEM
LAMPS
HEADLIGHT
!
HEADLIGHT BULB REPLACEMENT
Disconnect the coupler.
Remove the bulb.
Install new bulb in the reverse order of removal.
HEADLIGHT BEAM ADJUSTMENT
Adjust the headlight vertical beam by loosening the screw 1.
If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol
or soapy water to prevent premature bulb failure.
Head light: 12 V 40/40 W
E-28 ONLY
7.8 N•m (0.78 kgf-m, 5.6 lb-ft)
1.8 N•m
(0.18 kgf-m, 1.3 lb-ft)
PartShark.com
877-999-5686
ELECTRICAL SYSTEM 8-23
BRAKE LIGHT/TAILLIGHT
"
BULB REPLACEMENT
Disconnect the socket.
Remove the bulb.
Install new bulb in the reverse order of removal.
Brake light/taillight: 12 V 21/5 W
E-28 Only
If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol
or soapy water to prevent premature bulb failure.
PartShark.com
877-999-5686
8-24 ELECTRICAL SYSTEM
INDICATOR LIGHT
INSPECTION
INDICATOR LIGHT POSITION
RE NU
Bl/R
O/Bl
Bl/B
Steering
stem
head cover
ITEM
RE: Reverse indicator light O/Bl Bl/R
NU: Neutral indicator light O/Bl Bl/B
Bl/B
Bl/R
O/Bl
: Blue with Black tracer
: Blue with Red tracer
: Orange with Blue tracer
WIRE COLOR
Neutral indicator light
(Bl/B & O/Bl) Reverse indicator light
(Bl/R & O/Bl)
Steering
stem head
cover
Bl/B
Bl/R
O/Bl
: Orange with Blue tracer
: Blue with Black tracer
: Blue with Red tracer
WIRE COLOR
LB LR
PartShark.com
877-999-5686
ELECTRICAL SYSTEM 8-25
DIODE
Remove the fuel tank left side cover. (!7-5)
Remove the neutral switch diode 1.
Measure the voltage between the terminals using the multi cir-
cuit tester as indicated in the table below.
"09900-25008: Multi circuit tester set
#Tester knob indication: Diode test ($)
✽ More than 1.4 V (testers 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.
Unit: V
+ Tester probe
-
Tester
probe
A B C
A✽✽
B0.4  0.6 0.4  0 .6
C✽✽
PartShark.com
877-999-5686
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
IGNITION SWITCH
DIMMER SWITCH
ENGINE STOP SWITCH
STARTER BUTTON
BRAKE LIGHT LEVER SWITCH (L)
BRAKE LIGHT LEVER SWITCH (R)
NEUTRAL SWITCH
PARKING BRAKE SWITCH
Color
Position ROGr
Color
Position YWGr
Color
Position OO/W
Color
Position O/W Y/G
Color
Position BB
ON
OFF
BRAKE LIGHT PEDAL SWITCH
Color
Position OW/B
ON
OFF
Color
Position Terminal Terminal
ON
OFF
Neutral
Reverse
Others
Color
Position Bl B/W
R
Color
Position B/W B/Bl
ON
OFF
WIRE COLOR
B : Black
Bl : Blue
G : Green
Gr : Gray
O : Orange
R : Red
Y : Yellow
B/Bl : Black with Blue tracer
B/W : Black with White tracer
O/W : Orange with White tracer
O/G : Orange with Green tracer
W/B : White with Black tracer
Y/G : Yellow with Green tracer
PartShark.com
877-999-5686
ELECTRICAL SYSTEM 8-27
BATTERY
SPECIFICATIONS
a Anode plates
e Stopper
b Separator (fiberglass plate)
f Filter
c Cathode plates
g Terminal
d Upper cover breather
h Safety valve
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 electro-
lyte container.
Insert the nozzles of the electrolyte container
5 into the bat-
tery 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.
Type designation YTX9-BS
Capacity 12 V, 28.8 kC (8 Ah)/10 HR
PartShark.com
877-999-5686
8-28 ELECTRICAL SYSTEM
Make sure that air bubbles
6 are coming up into each elec-
trolyte container, and leave it in this position for more than 20
minutes.
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 bat-
tery top cover.
"
For initial charging, use a charger specially designed for MF
batteries.
* Never use anything except the specified battery.
* Once install the caps to the battery; do not remove
the caps.
* Do not tap the caps with a hammer when installing
them.
CORRECT INCORRECT
PartShark.com
877-999-5686
ELECTRICAL SYSTEM 8-29
"
SERVICING
Visually inspect the surface of the battery. If any signs of crack-
ing 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.
$09900-25008: Multi circuit tester set
"
Recharging time: 0.9 A for 5 to 10 hours or 4 A for 1 hour.
"
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.
* 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.
* When recharging the battery, remove the battery
from the vehicle.
* Do not remove the caps while recharging.
Be careful not to permit the charging current to
exceed 4 A at any time.
(V)
14
13
12
11
10
100 75 50 25 0 (%)
Battery charged condition
(at 0  40 ßC, 32 — 104 ßF)
Charging period
Stop charging
Time (Minutes)
0 102030405060
(V)
18
17
16
15
14
13
12
PartShark.com
877-999-5686
PartShark.com
877-999-5686
9
SERVICING INFORMATION 9-1
CONTENTS
SERVICING INFORMATION
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
PartShark.com
877-999-5686
9-2 SERVICING INFORMATION
TROUBLESHOOTING
ENGINE
Complaint Symptom and possible causes Remedy
Engine will not start
or is hard to start.
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.
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.
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.
Replace.
Replace.
Repair or replace.
Tighten.
See electrical section.
Adjust.
Adjust.
Clean or replace.
Clean and dry or replace.
Replace.
Replace.
Replace.
Replace.
Clean or replace.
Clean or replace.
Replace.
Clean or replace.
Clean or replace.
Engine stalls easily. 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.
Replace.
Replace.
Clean or replace.
Clean.
Adjust.
Engine is noisy. Excessive valve chatter
1. Excessive valve clearance.
2. Weak or broken valve spring.
3. Worn rocker arm and rocker arm shaft.
Noise seems to come from the piston
1. Worn piston.
2. Worn cylinder.
3. Carbon build-up in combustion chamber.
4. Worn piston pin or piston pin bore.
5. Worn piston ring or ring groove.
Noise seems to come from the cam chain
1. Stretched cam chain.
2. Worn cam chain sprocket.
3. Improperly working cam chain 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.
Adjust.
Replace.
Replace.
Replace.
Replace.
Clean.
Replace.
Replace.
Replace cam chain and
sprockets.
Replace cam chain and
sprockets.
Repair or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
PartShark.com
877-999-5686
SERVICING INFORMATION 9-3
Complaint Symptom and possible causes Remedy
Engine is noisy. Noise seems to come from the crankshaft
1. Worn or burnt bearing.
2. Big-end bearing worn or burnt.
3. Excessive thrust clearance.
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.
Noise seems to come from transfer
1. Worn down gears or shafts.
2. Damage to bearings/bushing.
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.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Adjust.
Adjust.
Replace.
Replace.
Replace
Adjust or replace.
Adjust or replace.
Slipping clutch. 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.
Adjust.
Replace.
Replace.
Replace.
Replace.
Dragging clutch. 1. Clutch control out of adjustment or too much play.
2. Some clutch springs weakened while others are not.
3. Distorted pressure plate or clutch plates.
4. Worn or damage clutch release mechanism.
Adjust.
Replace.
Replace.
Adjust or replace.
Transmission will not
shift.
1. Broken gearshift cam.
2. Distorted gearshift forks.
3. Worn gearshift shaft.
4. Worn or damage clutch release mechanism.
5. Improperly adjusted reverse cable.
Replace.
Replace.
Replace.
Adjust or replace.
Adjust.
Transmission will not
shift back.
1. Broken reverse shift cam.
2. Shift shafts are rubbing or sticky.
3. Distorted or worn gearshift forks.
4. Broken or damaged gearshift lever return spring.
Replace.
Repair
Replace.
Replace.
Transmission jumps
out of gear.
1. Worn shifting gears on driveshaft or countershaft.
2. Distorted or worn gearshift forks.
3. Weakened cam stopper spring on gearshift cam.
4. Worn gearshift lever stopper pin.
Replace.
Replace.
Replace.
Replace.
Transfer will not shift
or shift back.
1. Broken or worn sliding dog.
2. Broken or worn gearshift fork.
3. Worn gearshift cam.
4. Weakened cam stopper spring.
5. Worn gearshift fork shaft.
Replace.
Replace.
Replace.
Replace.
Replace.
PartShark.com
877-999-5686
9-4 SERVICING INFORMATION
Complaint Symptom and possible causes Remedy
Engine idles poorly. 1. Valve clearance out of adjustment.
2. Poor seating of valves.
3. Defective valve guides.
4. Worn rocker arm or arm shaft.
5. Defective generator.
6. Defective CDI unit.
7. Spark plug gap too wide.
8. Defective ignition coil resulting in weak sparking.
9. Float-chamber fuel level out of adjustment in carburetor.
10. Clogged jets.
11. Defective fuel valve.
12. Improperly set pilot screw.
Adjust.
Replace.
Replace.
Replace.
Replace.
Replace.
Adjust or replace.
Replace.
Adjust.
Clean.
Replace.
Adjust.
Engine runs poorly in
high speed range.
1. Valve springs wakened.
2. Valve timing out of adjustment.
3. Worn cams or rocker arms.
4. Spark plug gap too narrow.
5. Defective ignition coil.
6. Float-chamber fuel level tool low.
7. Clogged air cleaner element.
8. Clogged fuel pipe, resulting in inadequate fuel supply to
carburetor.
9. Defective fuel valve.
Replace.
Adjust.
Replace.
Adjust.
Replace.
Adjust.
Clean.
Clean and prime.
Replace.
Dirty or heavy
exhaust smoke.
1. Too much engine oil in the engine.
2. Worn piston rings or cylinder.
3. Worn valve guides.
4. Cylinder wall scored or scuffed.
5. Worn valve stems.
6. Defective stem seals.
Check with inspection window,
drain out excess oil.
Replace.
Replace.
Replace.
Replace.
Replace.
Engine lacks power. 1. Loss of valve clearance.
2. Weakened valve springs.
3. Valve timing out of adjustment.
4. Worn piston ring or cylinder.
5. Poor seating of valves.
6. Fouled spark plug.
7. Worn rocker arms or shafts.
8. Spark plug gap incorrect.
9. Clogged jets in carburetor.
10. Float-chamber fuel level out of adjustment.
11. Clogged air cleaner element.
12. Too much engine oil.
13. Sucking air around intake pipe.
Adjust.
Replace.
Adjust.
Replace.
Repair.
Clean or replace.
Replace.
Adjust or replace.
Clean.
Adjust.
Clean.
Drain out excess oil.
Retighten or replace.
Engine overheats. 1. Heavy carbon deposit on piston crown.
2. Not enough oil in the engine.
3. Defective oil pump or clogged oil circuit.
4. Fuel level too low in float chamber.
5. Air leak from intake pipe.
6. Use of incorrect engine oil.
Clean.
Add oil.
Replace or clean.
Adjust.
Retighten or replace.
Change.
PartShark.com
877-999-5686
SERVICING INFORMATION 9-5
DRIVE TRAIN
CARBURETOR
Complaint Symptom and possible causes Remedy
Power will not trans-
mit from the engine to
the rear wheel.
1. Broken drive and driven bevel gear teeth.
2. Broken propeller shaft serration.
3. Worn or broken rear axle serration.
4. Worn or damaged coupling joint serration.
5. Broken or damaged rear drive and driven bevel gears.
6. Worn or damaged universal joint.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Complaint Symptom and possible causes Remedy
Starting difficulty. 1. Clogged starter jet.
2. Clogged starter jet passage.
3. Air leaking from joint between starter body and carbure-
tor.
4. Improperly working starter (enricher) plunger.
Clean.
Clean.
Tighten, adjust or replace gas-
ket.
Adjust.
Idling or low-speed
trouble.
1. Clogged or loose pilot jet.
2. Clogged pilot jet passage.
3. Clogged pilot outlet port.
4. Clogged bypass port.
5. Starter (enricher) plunger not fully closed.
6. Improperly set pilot screw.
7. Incorrect float height.
Clean or tighten.
Clean.
Clean.
Clean.
Adjust.
Adjust.
Adjust.
Medium-or high
speed trouble.
1. Clogged main jet.
2. Clogged main air jet.
3. Clogged needle jet.
4. Improperly working throttle valve.
5. Clogged fuel filter.
6. Incorrect float height.
7. Starter (enricher) plunger not fully closed.
Clean.
Clean.
Clean.
Adjust.
Clean or replace.
Adjust.
Adjust.
Overflow and fuel
level fluctuations.
1. Worn or damaged needle valve.
2. Broken needle valve spring.
3. Improperly working float.
4. Foreign matter on the needle valve.
5. Incorrect float chamber fuel level.
Replace.
Replace.
Adjust or replace.
Clean or replace with needle
valve seat.
Adjust float height.
PartShark.com
877-999-5686
9-6 SERVICING INFORMATION
CHASSIS
Complaint Symptom and possible causes Remedy
Handling is too heavy
or stiff.
1. Improper front wheel alignment.
2. Insufficiently lubricated.
3. Low air pressure in front tires.
4. Tie rod ends tending to seize.
5. Linkage connections tending to seize.
Adjust.
Lubricate.
Adjust.
Replace.
Repair or replace.
Steering wobbles. 1. Unequally inflated tires.
2. Loose front wheel hub nuts.
3. Damaged or worn front wheel hub bearings.
4. Worn or loose tie rod ends.
5. Defective or incorrect front tires.
6. Damaged or worn wishbone arms and related bush-
ings.
7. Distorted front wheels.
8. Loose chassis nuts and bolts.
Regulate.
Tighten.
Replace.
Replace or tighten.
Replace.
Replace.
Replace.
Tighten.
Steering pulls to one
side.
1. Unequally inflated tires.
2. Improper front wheel alignment.
3. Worn front wheel hub bearings.
4. Distorted frame or wishbone.
5. Defective shock absorber.
Regulate.
Adjust.
Replace.
Repair or replace.
Replace.
Shocks felt in the
steering.
1. High tire pressure.
2. Worn steering linkage connections.
3. Loose suspension system bolts.
Regulate.
Replace.
Tighten.
Tires rapidly or
unevenly wear.
1. Worn or loose front wheel hub bearings.
2. Improper front wheel alignment.
Replace.
Adjust.
Steering too noisy. 1. Loose nuts and bolts.
2. Damaged or worn front wheel hub bearings.
3. Insufficiently lubricated.
Tighten.
Replace.
Lubricate.
Suspension too soft. 1. Weakened spring.
2. Shock absorber leaks oil.
Replace.
Replace.
Suspension too stiff. 1. Worn upper or lower wishbone arms and related bush-
ings.
2. Bent shock absorber rod.
Tighten.
Replace.
Suspension too
noisy.
1. Loose suspension system bolts.
2. Worn wishbone arms and related bushings.
3. Worn swingarm bushings.
Tighten.
Replace.
Replace.
Rear wheels wobble. 1. Distorted rear wheel rims.
2. Damage or worn rear brake panel bearings.
3. Defective or incorrect rear tires.
4. Loose rear wheel hub nuts.
5. Distorted rear axle.
6. Loosen rear axle housing mounting bolts.
7. Improper rear brake adjustment.
8. Damaged or worn rear swingarm and related bushings.
9. Rear shock absorber leaks oil.
10. Loose rear swingarm nut.
Replace.
Replace.
Replace.
Tighten.
Replace.
Tighten.
Adjust.
Replace.
Replace.
Tighten.
PartShark.com
877-999-5686
SERVICING INFORMATION 9-7
BRAKES
Complaint Symptom and possible causes Remedy
Poor braking.
(FRONT)
1. Insufficient brake fluid.
2. Air in brake fluid circuit.
3. Worn pads.
4. Worn disc.
Refill to level mark.
Bleed air out.
Replace.
Replace.
Poor braking.
(REAR)
1. Worn shoe linings.
2. Too much play on brake pedal or brake lever.
Replace.
Adjust.
Insufficient brake
power.
1. Leakage of brake fluid from hydraulic system.
2. Worn pads, worn lining.
3. Oil adhesion on engaging surface of pads.
4. Worn disc or bake drum.
5. Air in hydraulic system.
Repair or replace.
Replace.
Clean disc and pads.
Replace.
Bleed.
Brake squeaks. 1. Carbon adhesion on pad surface.
Carbon adhesion on lining surface.
2. Titled pad.
3. Loose front wheel axle or rear wheel axle.
4. Worn brake pads and linings.
5. Foreign material in brake fluid.
6. Clogged return port of master cylinder.
7. Wrongly fixed spring.
8. Caliper binding on caliper axles.
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.
Excessive brake lever
stroke.
1. Air in hydraulic system.
2. Insufficient brake fluid.
3. Improper quality of brake fluid.
Bleed.
Replenish fluid to specified
level and bleed air.
Replace with correct fluid.
Brake fluid leakage. 1. Insufficient tightening of connection joints.
2. Cracked hose.
3. Worn piston and/or cup.
Tighten to specified torque and
add brake fluid.
Replace.
Replace piston and/or cup.
PartShark.com
877-999-5686
9-8 SERVICING INFORMATION
ELECTRICAL
Complaint Symptom and possible causes Remedy
No sparking or poor
sparking.
1. Defective ignition coil.
2. Defective spark plug.
3. Defective generator.
4. Defective CDI unit.
5. Defective pickup coil.
Replace.
Replace.
Replace.
Replace.
Replace.
Spark plug is wet or
quickly becomes
fouled with carbon.
1. Excessively rich air/fuel mixture.
2. Excessively high idling speed.
3. Incorrect gasoline.
4. Dirty air cleaner element.
5. Incorrect spark plug (cold type).
Adjust carburetor.
Adjust carburetor.
Change.
Clean or replace.
Change to standard spark
plug.
Spark plug quickly
becomes fouled with
oil or carbon.
1. Worn piston ring.
2. Worn piston.
3. Worn cylinder.
4. Excessive valve-stem-to-valve-guide clearance.
5. Worn valve stem oil seal.
Replace.
Replace.
Replace.
Replace.
Replace.
Spark plug electrodes
overheat or burn.
1. Incorrect spark plug.
2. Overheated engine.
3. Loose spark plug.
4. Excessively lean air/fuel mixture.
Change to cold type spark
plug.
Tu r n - u p.
Tighten.
Adjust carburetor.
Generator does not
charge.
1. Open or short in lead wires, or loose lead connections.
2. Shorted, grounded or open generator coil.
3. Shorted or punctured regulator/rectifier.
Repair, replace or connect
properly.
Replace.
Replace.
Generator charges
but charging rate is
below specification.
1. Lead wires tend to get shorted, open-circuited, or
loosely connected at terminal.
2. Grounded or open-circuited stator coils or generator.
3. Defective regulator/rectifier.
Repair or tighten.
Replace.
Replace.
Generator over-
charges.
1. Internal short-circuit in the battery.
2. Damaged or defective regulator/rectifier.
Replace battery.
Replace.
Unstable charging. 1. Lead wire insulation frayed due to vibration, resulting in
intermittent shorting.
2. Internally shorted generator.
3. Defective regulator/rectifier.
Repair or replace.
Replace.
Replace.
Starter button does
not work.
1. Run down battery.
2. Defective switch contact.
3. Brushes do not seat properly on the commutator in the
starter motor.
4. Defective starter relay.
5. Defective neutral relay.
6. Defective emergency switch. (E-17)
7. Defective engine stop switch.
8. Defective neutral switch.
9. Defective parking brake switch.
10. Wiring connections loose or disconnected.
Recharge or replace.
Replace.
Repair or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Connect, tighten or repair.
PartShark.com
877-999-5686
SERVICING INFORMATION 9-9
BATTERY
Complaint Symptom and possible causes Remedy
Sulfation or spots on
surfaces of cell
plates.
1. Cracked battery case.
2. Battery has been left in a run-down condition for a long
time.
Replace.
Replace.
Battery runs down
quickly.
1. Incorrect charging method.
2. Battery cell plates have lost much of their active mate-
rial as a result of overcharging.
3. Internally shorted battery.
4. Old battery.
Check the generator, and regu-
lator/rectifier circuit connec-
tions, and make necessary
adjustments to obtain specified
charging operation.
Replace the battery and cor-
rect the charging system.
Replace.
Replace.
Reversed battery
polarity.
1. Improperly connected battery leads.
(i.e.,
- to
+ and
+ to
-)
Replace the battery and be
sure to connect it properly.
Battery discharged
too rapidly.
1. Dirty container top and sides.
2. Old battery.
Clean.
Replace.
Battery sulfation. 1. Incorrect charging rate.
(When not in use, the battery should be checked at
least once a month and properly charged if necessary,
to avoid sulfation.)
2. The battery was left unused in a cold climate for too
long.
Replace.
Replace the battery if badly
sulfated.
PartShark.com
877-999-5686
9-10 SERVICING INFORMATION
WIRING DIAGRAM
HI
LO
RUN
OFF
PUSH
CDI UNIT
REGULATOR/
RECTIFIER
FUSE BOX
IGNITION
COIL
TAIL LIGHT
BATTERY
1 FUSE : 20A
STARTER
MOTOR STARTER
RELAY
1
NEUTRAL
DIODE
GENERATOR
NEUTRAL
RELAY
NEUTRAL
SWITCH
IGNITION
SWITCH
HEADLIGHT
LIGHT
ON
OFF
R O Gr
BRAKE LIGHT
SWITCH (R) BRAKE LIGHT
SWITCH (L)
OFF
ON
B B/O
PARKING
BRAKE
SWITCH
OFF
ON
R B
OFF
ON
B B
NU : NEUTRAL INDICATOR LIGHT
RE : REVERSE INDICATOR LIGHT
INDICATOR LIGHT BRAKE LIGHT SWITCH
ENGINE STOP
SWITCH
DIMMER
SWITCH STARTER
BUTTON
NU RE
B
Bl
Gr
O
R
W
Y
B/Bl
B/Br
B/W
B/Y
B/R
B/G
B/O
Bl/B
Bl/R
G/W
O/Bl
O/W
W/B
W/Bl
Y/B
Y/G
WIRE COLORS
: Black
: Blue
: Gray
: Orange
: Red
: White
: Yellow
: Black with Blue tracer
: Black with Brown tracer
: Black with White tracer
: Black with Yellow tracer
: Black with Red tracer
: Black with Green tracer
: Black with Orange tracer
: Blue with Black tracer
: Blue with Red tracer
: Green with White tracer
: Orange with Blue tracer
: Orange with White tracer
: White with Black tracer
: White with Blue tracer
: Yellow with Black tracer
: Yellow with Green tracer
ON
OFF
O
W/B
15A
B/Bl
B/G
Y/B
O
Bl
R
W
B/W
Bl/B
Bl/R
W
B/W
B/W
B/Bl
B
W/B
B
B/O
B/Y
B/Bl
B/Br
B
B/R
B/G
Bl
O
Bl/R
Bl
Bl/B
B/Bl
B
B
B
B/Y
G/Y
Y
Y
Y
B/Y
G/W
O
W
W/Bl
B/W
B
B
B
R
B/W
O
W/B
B/Y
B/W
W
B/Bl
Gr
B/W
W/B
Gr
B/W
W/B
Gr
B/W
W/B
Gr
B/W
W/B
Bl/R
O/Bl
Bl/B
Bl/R
O
Bl
B/Y
B/Bl
B/Br
B
B/R
B/G
R
O
Gr
R
O
Gr
R
O
Gr
R
O
Gr
Bl/B
Bl/R
W
B/W
Bl
R
W
B/W
Bl
Bl/B
B/Bl
B/Bl
B/G
Y/B
O
B
B
B
B/Y
G/W
Y/B
B/W
R
Y/B
B/W
R
B/WB/WB/WB/W
Y
Y
Y
B/Y
G/W
Y
W
Gr
O
O/W
Y/G
Y
W
Gr
O
O/W
Y/G
O
W
W/Bl
B/W
B
B
B
R
B/W
R
R
R
R
B/R
G/W
B/W
W/Bl
Bl/R
W
B/Y
Bl/B
B/R
G/W
B/W
W/Bl
Bl/R
W
B/Y
Bl/B
O
W/B
B/Y
B/W
B
B/O
B
B/O
B
B/O
B
B/O
B
B/O
B
B
B
B
B
W/B
B/W
B/Bl
PartShark.com
877-999-5686
SERVICING INFORMATION 9-11
WIRING HARNESS, CABLE, AND HOSE ROUTING
WIRING HARNESS ROUTING
Ignition coil
Clamp
Wiring harness
Handlebar switch
Ignition swich
Reverse cable Clamp
Wiring harness
Battery Clamp
Brake light/Taillight
Clamp
Parking brake
Pilot lamp
Left brake switch
EC approval label
(E-28)
IECS label (E-28)
Clamp
Wiring harness
Set the generator coupler inside of the frame.
Neutral relay
Clamp
Wiring harness
Regulator/rectifier
Starter relay
Clamp Cut the tip of the clamp
after clamping
the several lead wire.
Starter motor
Battery
Generator
Clamp
Starter motor
Generator
Clamp
Starter motor Neutral switch
Brake pedal switch
Clamp
Cut the tip of
the clamp after
clamping the pedal
switch lead wire.
Brake light pedal switch
Battery
PartShark.com
877-999-5686
9-12 SERVICING INFORMATION
( )
Forward
Clamp
Clamp
Clamp
30ß
Generator
lead wire
Starter motor
lead wire
Neutral
switch
lead wire
Starter motor
Starter
motor
C
Starter
motor
lead wire
VIEW A VIEW B
Clamp
Handlebar switch (L)
Parking brake switch
Starter cable
Brake lever switch
Ignition switch
Pass the lead wire on the upper bracket.
Clamp
Front brake switch
10ß
B
A
A
VIEW C
Magneto cover
Grommet
7 NÆm (0.7 kgf-m, 5.0 lb-ft)
Set the coupler inside.
Neutral switch
lead wire
6 NÆm
0.6 kgf-m
4.5 lb-ft
Rear brake lamp
switch harness
Carburetor
drain hose
Battery
PartShark.com
877-999-5686
SERVICING INFORMATION 9-13
CABLE ROUTING
Throttle cable
Clamp
Parking brake cable
Brake hose
Reverse cable
Pass the throttle cable
in front of the parking
brake cable.
Pass the parking
brake cable
behind the brake
hose.
Starter cable
Clamp
E
Parking brake cable
Starter cablle
Pass the reverse cable
in front of the brake pipe.
Cable guide
Reverse cable
Throttle cable
DETAIL E
FRONT
DETAIL B DETAIL C DETAIL D
Pass the parking
brake cable
inside of the
rear brake cable.
Fix the rubber of the parking
brake cable with the cable guide.
Pass the parking brake cable
outside of the frame.
Parking brake cable
Rear brake cable Pass the parking brake cable
through the frame bracket.
Set the pin inside.
Rear brake cable
Brake cable pin
OUTSIDE
FRONT
FRONT
OUTSIDE Pass the parking cable
and throttle cable
under the frame.
Clamp
Parking brake
cable
Throttle
cable
Clamp the parking
cable with the throttle cable.
Pass the throttle cable
inside of the frame.
DETAIL A
Brake cable adjuster
Brake cable pin
Make sure that
the small-pitch
portion of the
cable spring
faces to
the pin.
Rear brake cable spring
FRONT
Pass the throttle cable between
the brake hose and handlebars.
Throttle cable
Pass the parking and throttle
cables under the frame.
D
C
Rear brake
cable Clamp
Clamp
Parking brake cable
Clamp
Pass the parking
brake cable under
the rear brake cable.
A
B
PartShark.com
877-999-5686
9-14 SERVICING INFORMATION
DETAIL G
OUTSIDE
Reverse cable
FRONT Set the pin outside
Reverse cable pin
DETAIL F
OUTSIDE
FRONT
Clamp the starter cable
with the wiring harness.
Clamp
Wiring harness
Starter cable
Clamp the starter cable
inside of the frame.
F
Starter cable
Clamp
Parking brake cable
Pass the starter cable
under the frame.
G
Clamp
Reverse cable
Do not give
too much play.
PartShark.com
877-999-5686
SERVICING INFORMATION 9-15
STEERING SHAFT SET-UP
Tighten the rear bolts
after tightening the front ones.
Clearance
PartShark.com
877-999-5686
9-16 SERVICING INFORMATION
CARBURETOR HOSE ROUTING
Air vent hose
Carburetor
Clamp
Clamp
Carburetor overflow hose
Left Right
Left Right
45ß
PartShark.com
877-999-5686
SERVICING INFORMATION 9-17
FRONT BRAKE HOSE ROUTING
Front Brake hose
Cable guide
VIEW C
VIEW D
VIEW B
SECT EE
(LH)
(RH)
Reverse cable
A
Pass the brake hose
in front of
the wiring harness.
Throttle cable
B
F
F
E
E
Foward
Brake hose guide
Clamp firmly.
After the brake hose union
touching to the stopper,
tighten the union bolt.
28ß
28ß
Clamp
the hose
firmly.
VIEW A
D
C
SECT FF
Clamp firmly.
Punched mark
Foward
Mark
Front
brake
pipe
0ß – 5ß
After the brake hose union
touching to the stopper,
tighten the union bolt.
Wiring harness
Cable guide
Mark
Mark
The white mark
faces front side.
Front brake pipe
Pass the brake pipe
behind the reverse cable.
Pass the brake hose
in front of
the throttle cable.
PartShark.com
877-999-5686
9-18 SERVICING INFORMATION
REAR BRAKE BREATHER HOSE ROUTING
Rear swingarm
Pass through the rear brake
breather hose into the hole
of the fuel tank plate.
VIEW A
VIEW H
SECT FF, GG
SECT EE
VIEW B
SECT CC
Rear brake
breather hose
Clip
Inside Outside
Rear brake
breather hose
G
G
F
F
E
B
A
E
H
Fuel tank
Rear brake cable
Parking brake cable
Rear brake
anchor panel
Pass through the rear brake breather hose
into the oblong hole of the swingarm plate.
Rear brake
breather hose
Parking brake cable
Inside Outside
Clamp
Clip
Rear brake
breather hose
30 — 40 mm
Inside Outside
Frame
Rear brake
breather hose
Insert the rear brake breather hose
to the breather hose union correctly.
Parking brake cable
Parking brake cable
Clip
SECT DD
Inside Outside
Parking brake cable
Rear brake
breather hose
Clamp
Rear brake
breather hose
Side plate
Pass the rear brake
breather hose outside
of the frame and
parking brake cable.
C
C
D
D
Clamp
NOTE:
*Make sure not to twist and deform
the rear brake breather hose.
(1.18 — 1.57 in)
Frame
Frame
PartShark.com
877-999-5686
SERVICING INFORMATION 9-19
FUEL HOSE ROUTING
Steering head cover
Fuel tank breather
hose No. 2
Fuel tank breather hose
Fuel tank
Spacer
Cushion
A
Cushion
FRAME
Fuel tank front cushion
Clip
Fuel hose Clip
4.5 NÆm
(0.45 kgf-m, 3.25 lb-ft)
Steering head cover
Connect the wide diameter side
of the breather hose No. 2. Fuel tnak breather hose No. 2
Ignition switch harness
Steering stem shaft
Set the breather hose into
the hole of the stem shaft.
SECT C  C
CC
F
Steering head cover
Ignition switch
harness
Handlebars
Handlebar
Pass through the breather hose
No. 2 under the harness.
Pass through the breather hose No. 2
between the handlebars and ignition switch.
Ignition switch
Fuel tank breather
hose No. 2
VIEW B
B
VIEW A
Connect the curved side of
the fuel hose to the fuel valve.
Fuel valve
Fuel cock vacuum hose Frame
Carburetor
Fuel hose
The end of the clip
faces back side.
The end of the clip
faces front side.
Fuel valve
PartShark.com
877-999-5686
9-20 SERVICING INFORMATION
REAR BRAKE CAM LEVER SET-UP
Brake panel
Spring
Brake lining indicator plate
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.
PartShark.com
877-999-5686
SERVICING INFORMATION 9-21
STEERING HEAD COVER SET-UP
Steering head cover
Clip
Steering head cover bracket
Fuel tank breather
hose No. 2
PartShark.com
877-999-5686
9-22 SERVICING INFORMATION
TAILLIGHT SET-UP
Rear fender
Taillight
Side reflector
Rear reflector
E-28 ONLY
PartShark.com
877-999-5686
SERVICING INFORMATION 9-23
SPECIAL TOOLS
09900-00410
Hexagon wrench set 09900-06106
Snap ring pliers 09900-06107
Snap ring pliers 09900-06108
Snap ring pliers 09900-09004
Impact driver set
09900-20101
Vernier calipers
09900-20202
Micrometer
(1/100 mm,
2550 mm)
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
PartShark.com
877-999-5686
9-24 SERVICING INFORMATION
09913-85210
Bearing/oil seal
installer
09915-64510
Compression gauge
set
09918-02410 or
09918-03810
(Adaptor) 09915-74511
Oil pressure gauge
09915-74512
Oil pressure gauge
adaptor 09916-10911
Valve lapper set
09916-14510
Valve spring com-
pressor
09916-14910
Valve spring com-
pressor attachment
09916-21111
09916-24900
Valve seat cutter set
09916-24450
Solid pilot
(N-100-5.52)
09916-22480
Solid pilot
(N-140-5.5)
09916-24935
Valve seat cutter
(N-608) 09916-34542
Reamer handle
09916-34550
Valve guide reamer
(5.5 mm)
09916-34561
Valve guide reamer
(11.3 mm)
09916-44910
Valve guide
remover/installer
09916-84511
Tweezers
09920-13120
Crankcase separa-
tor
09920-53730
Clutch sleeve hub
holder 09921-20210
Bearing puller 09921-20240
Bearing remover set
09921-21820
Bearing locknut
wrench 09921-21910
Bearing holder 09923-74510
Bearing remover 09924-84510
Bearing installer set 09930-30104
Sliding shaft
PartShark.com
877-999-5686
SERVICING INFORMATION 9-25
NOTE:
When ordering a special tool, please confirm whether it is available or not.
09930-10121
Spark plug wrench
set 09930-30721
Rotor remover 09930-35010
Rotor remover 09930-31921
Rotor remover 09930-44520
Rotor holder
09930-73150
Output shaft holder 09950-81910
Remover
PartShark.com
877-999-5686
9-26 SERVICING INFORMATION
TIGHTENING TORQUE
ENGINE
ITEM N•m kgf-m lb-ft
Cylinder head cover bolt 10 1.0 7.0
Camshaft sprocket bolt 11 1.1 8.0
Cylinder head nut (M8) 23 2.3 16.5
Cylinder head nut (M6) 10 1.0 7.0
Cylinder base nut (M6) 10 1.0 7.0
Cam chain tensioner mounting bolt 10 1.0 7.0
Cam chain tension adjuster spring holder bolt 8 0.8 6.0
Neutral switch bolt 7 0.7 5.0
Spark plug 18 1.8 13.0
Rocker arm shaft bolt 9 0.9 6.5
Valve clearance adjuster locknut 14 1.4 10.0
Crankcase bolt 11 1.1 8.0
Valve timing inspection plug 23 2.3 16.5
Clutch shoe nut 140 14.0 101.5
Clutch sleeve hub nut 100 1.0 72.5
Clutch adjuster lock nut 23 2.3 16.5
Clutch adjuster cap 15 1.5 11.0
Generator rotor nut 160 16.0 115.5
Generator cover cap 15 1.5 11.0
Starter clutch bolt 26 2.6 19.0
Exhaust pipe nut 23 2.3 16.5
Muffler mounting bolt/nut 23 2.3 16.5
Muffler connecting bolt 23 2.3 16.5
Spark arrester bolt 11 1.1 8.0
Engine oil drain plug 21 2.1 15.0
Secondary drive bevel gear nut 100 10.0 72.5
Secondary driven bevel gear nut 100 10.0 72.5
Engine mounting bolt/nut 66 6.6 48.0
Engine mounting bracket bolt 23 2.3 16.5
Starter motor lead wire nut 6 0.6 4.5
Starter motor mounting bolt 10 1.0 7.0
PartShark.com
877-999-5686
SERVICING INFORMATION 9-27
DRIVE TRAIN
CHASSIS
ITEM N•m kgf-m lb-ft
Final gear case cover bolt 26 2.6 19.0
Pinion gear bearing locknut 100 10.0 72.5
Rear drive gear oil filler plug 26 2.6 19.0
Rear drive gear oil drain plug 26 2.6 19.0
Rear axle housing set bolt/nut (RH) 60 6.0 43.5
Rear axle housing set bolt/nut (LH) 65 6.5 47.0
Rear axle housing/final gear case bolt 65 6.5 47.0
ITEM N•m kgf-m lb-ft
Handlebar clamp bolt 23 2.3 16.5
Steering shaft holder bolt 23 2.3 16.5
Steering shaft nut 49 4.9 35.5
Wishbone arm pivot bolt/nut (upper and lower) 65 6.5 47.0
Wheel hub nut (front) 65 6.5 47.0
Wheel hub nut (rear) 138 13.8 99.9
Wheel set nut (front and rear) 50 5.0 36.0
Steering knuckle nut (upper and lower) 29 2.9 21.0
Front shock absorber mounting bolt/nut (upper and
lower) 60 6.0 43.5
Tie rod end nut 29 2.9 21.0
Tie rod lock nut 29 2.9 21.0
Front brake air bleeder valve 6.0 0.6 4.4
Front brake caliper mounting bolt 26 2.6 19.0
Front brake pipe nut (Upper and lower) 16 1.6 11.6
Front brake pad mounting pin 18 1.8 13.0
Front brake caliper holder pin 18 1.8 13.0
Front brake caliper holder slide pin 23 2.3 16.5
Front brake master cylinder mounting bolt 10 1.0 7.0
Front brake hose union bolt 23 2.3 16.5
Front brake disc bolt 23 2.3 16.5
Front brake disc plate mounting bolt 23 2.3 16.5
Footrest bolt (M8) 26 2.6 19.0
Footrest bolt (M10) 55 5.5 40.0
Rear shock absorber mounting bolt/nut (Upper) 78 7.8 55.0
Rear shock absorber mounting bolt/nut (Lower) 60 6.0 43.5
Swingarm pivot bolt/nut 85 8.5 61.5
Rear brake cam lever bolt/nut 11 1.1 8.0
Rear brake pedal mounting bolt 11 1.0 8.0
Rear brake panel mounting nut 60 6.0 43.5
PartShark.com
877-999-5686
9-28 SERVICING INFORMATION
TIGHTENING TORQUE CHART
For other nuts and bolts not listed in the preceding page, refer to this chart:
Bolt Diameter
A
AA
A (mm)
Conventional or  4 marked bolt 7 marked bolt
N•m kgf-m lb-ft N•m kgf-m lb-ft
4 1.5 0.15 1.0 2.3 0.23 1.5
5 3 0.3 2.0 4.5 0.45 3.0
6 5.5 0.55 4.0 10 1.0 7.0
8 13 1.3 9.5 23 2.3 16.5
10 29 2.9 21.0 50 5.0 36.0
12 45 4.5 32.5 85 8.5 61.5
14 65 6.5 47.0 135 13.5 97.5
16 105 10.5 76.0 210 21.0 152.0
18 160 16.0 115.5 240 24.0 173.5
Conventional bolt 4 marked bolt 7 marked bolt
PartShark.com
877-999-5686
SERVICING INFORMATION 9-29
SERVICE DATA
VALVE + GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diam. IN. 32
(1.3)
EX. 28
(1.1)
Tappet clearance (when cold) IN. 0.03  0 .08
(0.001  0 .003)
EX. 0.08  0 .13
(0.003  0 .005)
Valve guide to valve stem
clearance IN. 0.010  0 .037
(0.0004  0 .0015)
EX. 0.030  0 .057
(0.0012  0 .0024)
Valve stem deflection IN. & EX. 0.35
(0.014)
Valve guide I.D. IN. & EX. 5.500  5 .512
(0.2165  0 .2170)
Valve stem O.D. IN. 5.475  5 .490
(0.2156  0 .2161)
EX. 5.455  5 .470
(0.2148  0 .2154)
Valve stem runout IN. & EX. 0.05
(0.002)
Valve head thickness IN. & EX. 0.5
(0.02)
Valve stem end length IN. & EX. 2.5
(0.10)
Valve seat width IN. & EX. 0.88  1 .08
(0.035  0 .043)
Valve head radial runout IN. & EX. 0.03
(0.001)
Valve spring free length IN. & EX. 43.0
(1.69)
Valve spring tension
IN. & EX.
256  2 94 N
(26.1  3 0.0 kgf, 57.5  66 .1 lbs)
at length 36.6 mm (1.44 in)
PartShark.com
877-999-5686
9-30 SERVICING INFORMATION
CAMSHAFT + CYLINDER HEAD Unit: mm (in)
CYLINDER + PISTON + PISTON RING Unit: mm (in)
ITEM STANDARD LIMIT
Cam height IN. 33.780 33.820
(1.3299 1.3315) 33.480
(1.3181)
EX. 32.990 33.030
(1.2988 1.3004) 32.690
(1.2870)
Camshaft journal oil clearance 0.036  0.066
(0.0014 0.0026) 0.150
(0.0059)
Camshaft journal holder I.D. 22.012 22.025
(0.8666 0.8671)
Camshaft journal O.D. 21.959 21.976
(0.8645 0.8652)
Camshaft runout 0.10
(0.004)
Rocker arm I.D. IN. & EX. 12.000  12.018
(0.4724 0.4731)
Rocker arm shaft O.D. IN. & EX. 11.977  11.995
(0.4715 0.4722)
Cylinder head distortion 0.05
(0.002)
Cylinder head cover distortion 0.05
(0.002)
ITEM STANDARD LIMIT
Compression pressure 1 400 kPa
(14.0 kgf/cm2, 199 psi)
1 200 kPa
(12.0 kgf/cm2,
171 psi)
Piston to cylinder clearance 0.040  0. 050
(0.0016  0. 0020) 0.120
(0.0047)
Cylinder bore 66.000  66. 015
(2.5984  2. 5990) 66.090
(2.6020)
Piston diam. 65.955  65. 970
(2.5966  2. 5972)
Measure at 18 mm (0.71 in) from the skirt end.
65.880
(2.5937)
Cylinder distortion 0.05
(0.002)
Piston ring free end gap 1st R Approx. 8.7 (0.34) 7.0
(0.28)
2nd R Approx. 9.0 (0.35) 7.2
(0.28)
Piston ring end gap 1st 0.10  0. 25
(0.004  0. 010) 0.50
(0.020)
2nd 0.10  0. 25
(0.004  0. 010) 0.5
(0.020)
Piston ring to groove clearance 1st  0.180
(0.007)
2nd  0.150
(0.006)
Piston ring groove width 1st 1.01  1. 03
(0.0398  0. 0406)
2nd 1.21  1. 23
(0.0476  0. 0484)
Oil 2.01  2. 03
(0.0791  0. 0799)
PartShark.com
877-999-5686
SERVICING INFORMATION 9-31
CONROD + CRANKSHAFT Unit: mm (in)
OIL PUMP
CLUTCH Unit: mm (in)
ITEM STANDARD LIMIT
Piston ring thickness 1st 0.97  0.99
(0.038  0.039)
2nd 1.17  1.19
(0.046  0.047)
Piston pin bore 16.002  16.008
(0.6300  0.6302)
16.030
(0.6311)
Piston pin O.D. 15.992  16.000
(0.6296  0.6299)
15.980
(0.6291)
ITEM STANDARD LIMIT
Conrod small end I.D. 16.006  16 .014
(0.6302  0.6305)
16.040
(0.6315)
Conrod deflection 3.0
(0.12)
Conrod big end side clearance 0.10  0. 45
(0.004  0.018) 1.0
(0.04)
Conrod big end width 17.95  18 .00
(0.707  0.709)
Crank web to web width 53.0 – 0.1
(2.087 – 0.004)
Crankshaft runout 0.08
(0.003)
ITEM STANDARD LIMIT
Oil pressure (at 60 C, 140 F) 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.
ITEM STANDARD LIMIT
Clutch release screw 1/16  1 /8 turn back
Drive plate thickness 2.7  2. 9
(0.106  0.114)
2.4
(0.094)
Drive plate claw width 11.9  12 .0
(0.469  0.472)
11.0
(0.433)
Driven plate distortion 0.10
(0.004)
Clutch spring free length 28.9
(1.14)
27.5
(1.08)
Clutch wheel I.D. 116.00  1 16.15
(4.567  4.573)
116.5
(4.59)
Clutch shoe No groove at
any part
Clutch engagement r/min. 1 700  2 100 r/min
Clutch lock-up r/min. 3 100  3 700 r/min
PartShark.com
877-999-5686
9-32 SERVICING INFORMATION
DRIVE TRAIN Unit: mm (in) Except ratio
CARBRETOR
ITEM STANDARD LIMIT
Primary reduction ratio 3.047 (64/21)
Secondary reduction ratio 1.133 (17/15)
Final reduction ratio 3.200 (32/10)
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)
Shift fork to groove clearance 0.10  0.30
(0.004  0.012) 0.5
(0.020)
Shift fork groove width 4.50  4.6 0
(0.169  0.173)
Shift fork thickness 4.30  4.40
(0.169  0.173)
Gearshift lever height 0  10
(0  0 .393)
Secondary bevel gear
backlash
0.03  0.15
(0.001  0.006)
Rear drive (final) bevel gear
backlash
0.05  0.30
(0.002  0.012)
ITEM SPECIFICATION
E-19, 28 E-33
Carburetor type MIKUNI BSR29 ←
Bore size 29 mm
(1.14 in) ←
I.D. No. 21G0 21G1
Idle r/min 1 500 – 100 r/min ←
Float height 13.0 – 1.0 mm
(0.51 – 0.04 in) ←
Main jet (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 PRE-SET
Throttle cable play 3  5 mm
(0.12  0.2 0 in) ←
Starter (enricher) plunger cable
play
0.5  1.0 mm
(0.02  0.0 4 in) ←
PartShark.com
877-999-5686
SERVICING INFORMATION 9-33
ELECTRICAL Unit: mm (in)
WATTAGE Unit: W
ITEM SPECIFICATION NOTE
Spark plug Type NGK: DR7EA
DENSO: X22ESR-U
Gap 0.6  0.7
(0.024  0.028)
Spark performance Over 8 (0.3) at 1 atm.
Ignition coil resistance Primary 0.05  1.0 Ω
ΩΩ
Ω
Terminal 
Terminal
Secondary 10.5  1 9.0 kΩ
ΩΩ
Ω Plug cap 
Terminal
Ignition coil primary peak voltage 120 V and more
+: B/W
-: W/Bl
Generator coil resistance Pick-up 80  155 Ω
ΩΩ
Ω Bl/Y  G/W
Charging 0.5  1. 2 Ω
ΩΩ
Ω Y  Y
Pick-up coil peak voltage 4.0 V and more
+: G/W
-: Bl/Y
Generator no-load voltage
(When engine is cold) 65 V (AC) and more at 5 000 r/min
Generator Max. output Approx. 150 W at 5 000 r/min
Regulated voltage 14.0  15.5 V at 5 000 r/min
Starter relay resistance 3  6 Ω
ΩΩ
Ω
Battery Type designation YTX9-BS
Capacity 12V 28.8 kC (8 Ah)/10HR
Fuse size 20 A
ITEM SPECIFICATION
Headlight HI 40
LO 40
Brake light/Taillight 21/5
Reverse indicator light 3
Neutral indicator light 3
PartShark.com
877-999-5686
9-34 SERVICING INFORMATION
BRAKE + WHEEL Unit: mm (in)
TIRE PRESSURE
VEHICLE LOAD CAPACITY LIMIT: 110 kg (243 lbs)
ITEM STANDARD/SPECIFICATION LIMIT
Rear brake lever play 3  5
(0.12  0.20)
Rear brake pedal free travel 20  30
(0.79  1.18)
Brake disc thickness Front 2.8  3.2
(0.110  0.126)
2.5
(0.098)
Brake disc runout Front  0.30
(0.012)
Brake drum I.D. Rear  140.7
(5.54)
Master cylinder bore Front 12.700  12.743
(0.5000  0.5017)
Master cylinder piston diam. Front 12.657  12.684
(0.4983  0.4994)
Brake caliper cylinder bore Front 32.030  32.080
(1.2610 1. 2630)
Brake caliper piston diam. Front 31.948  31.998
(1.2578  1.2598)
Brake fluid type DOT 4
Turning radius 2.7 m (8.9 ft)
Toe-in (with 75 kg, 165 lbs) 5 – 4
(0.20 – 0.16)
Camber 0
Caster 7 40
Wheel rim size Front 10  5.5 A T
Rear 9  8.0 AT
Tire size Front AT22  7-10 ✩✩
✩✩✩✩
✩✩
Rear AT20  10-9 ✩
✩✩
✩
Tire tread depth Front  4.0
(0.16)
Rear  4.0
(0.16)
Wheel axle runout Rear  3.0
(0.12)
COLD INFLATION
TIRE PRESSURE kPa kgf/cm2psi
FRONT 30 0.30 4.4
REAR 25 0.25 3.6
PartShark.com
877-999-5686
SERVICING INFORMATION 9-35
FUEL + OIL
ITEM SPECIFICATION NOTE
Fuel type 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.
E-28, 33
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended. The others
Fuel tank including reserve 10.6 L
(2.8/2.3 US/lmp gal)
Reserve 2.6 L
(0.7/0.6 US/lmp gal)
Engine oil type SAE 10W-40, API SF or SG
Engine oil capacity Change 2 200 ml
(2.3/1.9 US/lmp qt)
Filter change 2 300 ml
(2.4/2.0 US/lmp qt)
Overhaul 2 500 ml
(2.6/2.2 US/lmp qt)
Final gear oil type Hypoid gear oil SAE #90, API grade GL-5
Final gear oil capacity 190 ml
(6.4/6.7 US/lmp oz)
PartShark.com
877-999-5686
PartShark.com
877-999-5686
LT-Z250K5 (05-MODEL) 10-1
CONTENTS
LT-Z250K5 (05-MODEL)
10
This chapter describes specifications, service data and servicing procedures which differ from
those of the LT-Z250K4 (04-MODEL).
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.
SPECIFICATIONS......................................................................................... 10- 2
SERVICE DATA ............................................................................................ 10- 3
TIGHTENING TORQUE................................................................................. 10-10
FRONT BRAKE CALIPER MOUNTING BOLT............................................. 10-10
FRONT BRAKE HOSE ROUTING ................................................................ 10-11
PartShark.com
877-999-5686
10-2 LT-Z250K5 (05-MODEL)
SPECIFICATIONS
DIMENSIONS AND DRY MASS
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)
ENGINE
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 cm3 (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, Low .............................................................................. 3.083 (37/12)
2nd............................................................................... 1.933 (29/15)
3rd................................................................................ 1.388 (25/18)
4th................................................................................ 1.095 (23/21)
Top ............................................................................... 0.913 (21/23)
Reverse........................................................................ 2.833 (34/12)
Final reduction ratio............................................................................. 3.200 (32/10)
CHASSIS
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
ELECTRICAL
Ignition type......................................................................................... Electronic ignition (CDI)
Ignition 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 change........................................................................... 190 ml (6.4/6.7 US/Imp oz)
PartShark.com
877-999-5686
LT-Z250K5 (05-MODEL) 10-3
SERVICE DATA
VALVE + GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diam. IN. 32
(1.3)
EX. 28
(1.1)
Tappet clearance (when cold) IN. 0.03  0.08
(0.001  0.003)
EX. 0.08  0.13
(0.003  0.005)
Valve guide to valve stem
clearance IN. 0.010  0.037
(0.0004  0.0015)
EX. 0.030  0.057
(0.0012  0.0024)
Valve stem deflection IN. & EX. 0.35
(0.014)
Valve guide I.D. IN. & EX. 5.500  5.512
(0.2165  0.2170)
Valve stem O.D. IN. 5.475  5.490
(0.2156  0.2161)
EX. 5.455  5.470
(0.2148  0.2154)
Valve stem runout IN. & EX. 0.05
(0.002)
Valve head thickness IN. & EX. 0.5
(0.02)
Valve stem end length IN. & EX. 2.5
(0.10)
Valve seat width IN. & EX. 0.88  1.08
(0.035  0.043)
Valve head radial runout IN. & EX. 0.03
(0.001)
Valve spring free length IN. & EX. 43.0
(1.69)
Valve spring tension IN. & EX. 256  294 N
(26.1  30.0 kgf, 57.5  66.1 lbs)
at length 36.6 mm (1.44 in)
PartShark.com
877-999-5686
10-4 LT-Z250K5 (05-MODEL)
CAMSHAFT + CYLINDER HEAD Unit: mm (in)
CYLINDER + PISTON + PISTON RING Unit: mm (in)
ITEM STANDARD LIMIT
Cam height IN. 33.780  33.820
(1.3299  1.3315) 33.480
(1.3181)
EX. 32.990  33.030
(1.2988  1.3004) 32.690
(1.2870)
Camshaft journal oil clearance 0.036  0.066
(0.0014  0.0026) 0.150
(0.0059)
Camshaft journal holder I.D. 22.012  22.025
(0.8666  0.8671)
Camshaft journal O.D. 21.959  21.976
(0.8645  0.8652)
Camshaft runout 0.10
(0.004)
Rocker arm I.D. IN. & EX. 12.000  12.018
(0.4724  0.4731)
Rocker arm shaft O.D. IN. & EX. 11.977  11.995
(0.4715  0.4722)
Cylinder head distortion 0.05
(0.002)
Cylinder head cover distortion 0.05
(0.002)
ITEM STANDARD LIMIT
Compression pressure 1 400 kPa
(14.0 kgf/cm2, 199 psi)
1 200 kPa
(12.0 kgf/cm2,
171 psi)
Piston to cylinder clearance 0.040  0.050
(0.0016  0.0020) 0.120
(0.0047)
Cylinder bore 66.000  66.015
(2.5984  2.5990) 66.090
(2.6020)
Piston diam. 65.955  65.970
(2.5966  2.5972)
Measure at 18 mm (0.71 in) from the skirt end.
65.880
(2.5937)
Cylinder distortion 0.05
(0.002)
Piston ring free end gap 1st R Approx. 8.7 (0.34) 7.0
(0.28)
2nd R Approx. 9.0 (0.35) 7.2
(0.28)
Piston ring end gap 1st 0.10  0.25
(0.004  0.010) 0.50
(0.020)
2nd 0.10  0.25
(0.004  0.010) 0.5
(0.020)
Piston ring to groove clearance 1st  0.180
(0.007)
2nd  0.150
(0.006)
PartShark.com
877-999-5686
LT-Z250K5 (05-MODEL) 10-5
CONROD + CRANKSHAFT Unit: mm (in)
OIL PUMP
CLUTCH Unit: mm (in)
ITEM STANDARD LIMIT
Conrod small end I.D. 16.006  16.014
(0.6302  0.6305) 16.040
(0.6315)
Conrod deflection 3.0
(0.12)
Conrod big end side clearance 0.10  0.45
(0.004  0.018) 1.0
(0.04)
Conrod big end width 17.95  18.00
(0.707  0.709)
Crank web to web width 53.0 – 0.1
(2.087 – 0.004)
Crankshaft runout 0.08
(0.003)
ITEM STANDARD LIMIT
Oil pressure (at 60 C, 140 F) 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
ITEM STANDARD LIMIT
Clutch release screw 1/16  1/8 turn back
Drive plate thickness 2.7  2.9
(0.106  0.114) 2.4
(0.094)
Drive plate claw width 11.9  12.0
(0.469  0.472) 11.0
(0.433)
Driven plate distortion 0.10
(0.004)
Clutch spring free length 28.9
(1.14) 27.5
(1.08)
Clutch wheel I.D. 116.00  116.15
(4.567  4.573) 116.5
(4.59)
Clutch shoe No groove at
any part
Clutch engagement r/min 1 700  2 100 r/min
Clutch lock-up r/min 3 100  3 700 r/min
PartShark.com
877-999-5686
10-6 LT-Z250K5 (05-MODEL)
DRIVE TRAIN Unit: mm (in) Except ratio
CARBRETOR
ITEM STANDARD LIMIT
Primary reduction ratio 3.047 (64/21)
Secondary reduction ratio 1.133 (17/15)
Final reduction ratio 3.200 (32/10)
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)
Shift fork to groove clearance 0.10  0.30
(0.004  0.012) 0.5
(0.020)
Shift fork groove width 4.50  4.60
(0.169  0.173)
Shift fork thickness 4.30  4.40
(0.169  0.173)
Gearshift lever height 0  10
(0  0.393)
Secondary bevel gear backlash 0.03  0.15
(0.001  0.006)
Rear drive (final) bevel gear back-
lash 0.05  0.30
(0.002  0.012)
ITEM SPECIFICATION
E-19, 28 E-33
Carburetor type MIKUNI BSR29 ←
Bore size 29 mm
(1.14 in) ←
I.D. No. 21G0 21G1
Idle r/min 1 500 – 100 r/min ←
Float height 13.0 – 1.0 mm
(0.51 – 0.04 in) ←
Main jet (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 and 1/2 turns back PRE-SET
Throttle cable play 3  5 mm
(0.12  0.20 in) ←
Starter (enricher) plunger cable
play 0.5  1.0 mm
(0.02  0.04 in) ←
PartShark.com
877-999-5686
LT-Z250K5 (05-MODEL) 10-7
ELECTRICAL Unit: mm (in)
WATTAGE Unit: W
ITEM SPECIFICATION NOTE
Spark plug Type NGK: DR7EA
DENSO: X22ESR-U
Gap 0.6  0.7
(0.024  0.028)
Spark performance Over 8 (0.3) at 1 atm.
Ignition coil resistance Primary 0.05  1.0 Ω Terminal 
Terminal
Secondary 10.5  19.0 k Ω Plug cap 
Terminal
Ignition coil primary peak voltage 120 V and more +: B/W -: W/Bl
Generator coil resistance Pick-up 80  155 Ω Bl/Y  G/W
Charging 0.5  1.2 Ω Y  Y
Pick-up coil peak voltage 4.0 V and more +: G/W -: Bl/Y
Generator no-load voltage
(When engine is cold) 65 V (AC) and more at 5 000 r/min
Generator Max. output Approx. 150 W at 5 000 r/min
Regulated voltage 14.0  15.5 V at 5 000 r/min
Starter relay resistance 3  6 Ω
Battery Type designation YTX9-BS
Capacity 12V 28.8 kC (8 Ah)/10HR
Fuse size 20 A
ITEM SPECIFICATION
Headlight HI 40
LO 40
Brake light/Taillight 21/5
Reverse indicator light 3
Neutral indicator light 3
PartShark.com
877-999-5686
10-8 LT-Z250K5 (05-MODEL)
BRAKE + WHEEL Unit: mm (in)
TIRE PRESSURE
VEHICLE LOAD CAPACITY LIMIT: 110 kg (243 lbs)
ITEM STANDARD/SPECIFICATION LIMIT
Rear brake lever play 3  5
(0.12  0.20)
Rear brake pedal free travel 20  30
(0.79  1.18)
Brake disc thickness Front 2.8  3.2
(0.110  0.126) 2.5
(0.098)
Brake disc runout Front  0.30
(0.012)
Brake drum I.D. Rear  140.7
(5.54)
Master cylinder bore Front 12.700  12.743
(0.5000  0.5017)
Master cylinder piston diam. Front 12.657  12.684
(0.4983  0.4994)
Brake caliper cylinder bore Front 32.030  32.080
(1.2610 1.2630)
Brake caliper piston diam. Front 31.948  31.998
(1.2578  1.2598)
Brake fluid type DOT 4
Turning radius 2.7 m (8.9 ft)
Toe-in (with 75 kg, 165 lbs) 5 – 4
(0.20 – 0.16)
Camber 0
Caster 7 40
Wheel rim size Front 10  5.5 AT
Rear 9  8.0 AT
Tire size Front AT22  7-10 
Rear AT20  10-9
Tire tread depth Front  4.0
(0.16)
Rear  4.0
(0.16)
Wheel axle runout Rear  3.0
(0.12)
COLD INFLATION
TIRE PRESSURE kPa kgf/cm2psi
FRONT 30 0.30 4.4
REAR 25 0.25 3.6
PartShark.com
877-999-5686
LT-Z250K5 (05-MODEL) 10-9
FUEL + OIL
ITEM SPECIFICATION NOTE
Fuel type 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.
E-28, 33
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended. The others
Fuel tank capacity including
reserve 10.6 L
(2.8/2.3 US/lmp gal)
Reserve 2.6 L
(0.7/0.6 US/lmp gal)
Engine oil type SAE 10W-40, API SF or SG
Engine oil capacity Change 2 200 ml
(2.3/1.9 US/lmp qt)
Filter change 2 300 ml
(2.4/2.0 US/lmp qt)
Overhaul 2 500 ml
(2.6/2.2 US/lmp qt)
Final gear oil type Hypoid gear oil SAE #90, API grade GL-5
Final gear oil capacity 190 ml
(6.4/6.7 US/lmp oz)
PartShark.com
877-999-5686
10-10 LT-Z250K5 (05-MODEL)
TIGHTENING TORQUE
CHASSIS
FRONT BRAKE CALIPER MOUNTING BOLT
Apply THREAD LOCK SUPER 1360 to the caliper mounting bolts before tightening them.
99000-32130: THREAD LOCK SUPER 1360
ITEM N•m kgf-m lb-ft
Handlebar clamp bolt 23 2.3 16.5
Steering shaft holder bolt 23 2.3 16.5
Steering shaft nut 49 4.9 35.5
Wishbone arm pivot bolt/nut (upper and lower) 65 6.5 47.0
Wheel hub nut (front) 65 6.5 47.0
Wheel hub nut (rear) 138 13.8 99.9
Wheel set nut (front and rear) * 60 * 6.0 * 43.5
Steering knuckle nut (upper and lower) 29 2.9 21.0
Front shock absorber mounting bolt/nut (upper and
lower) 60 6.0 43.5
Tie rod end nut 29 2.9 21.0
Tie rod lock nut 29 2.9 21.0
Front brake air bleeder valve 6.0 0.6 4.4
Front brake caliper mounting bolt 26 2.6 19.0
Front brake pipe nut (Upper and lower) 16 1.6 11.6
Front brake pad mounting pin 18 1.8 13.0
Front brake caliper holder pin 18 1.8 13.0
Front brake caliper holder slide pin 23 2.3 16.5
Front brake master cylinder mounting bolt 10 1.0 7.0
Front brake hose union bolt 23 2.3 16.5
Front brake disc bolt 23 2.3 16.5
Front brake disc plate mounting bolt 23 2.3 16.5
Footrest bolt (M8) 26 2.6 19.0
Footrest bolt (M10) 55 5.5 40.0
Rear shock absorber mounting bolt/nut (Upper) 78 7.8 55.0
Rear shock absorber mounting bolt/nut (Lower) 60 6.0 43.5
Swingarm pivot bolt/nut 85 8.5 61.5
Rear brake cam lever bolt/nut 11 1.1 8.0
Rear brake pedal mounting bolt 11 1.0 8.0
Rear brake panel mounting nut 60 6.0 43.5
PartShark.com
877-999-5686
LT-Z250K5 (05-MODEL) 10-11
FRONT BRAKE HOSE ROUTING
Front Brake hose
Cable guide
VIEW C
VIEW D
VIEW B
SECT E  E
(LH)
(RH)
Reverse cable
A
Pass the brake hose
in front of
the wiring harness.
Throttle cable
B
F
F
E
E
Foward
Brake hose guide
Clamp firmly.
After the brake hose union
touching to the stopper,
tighten the union bolt.
28
28
Clamp
the hose
firmly.
VIEW A
D
C
SECT F  F
Clamp firmly.
Punched mark
Foward
Mark
Front
brake
pipe
0 – 5
After the brake hose union
touching to the stopper,
tighten the union bolt.
Wiring harness
Cable guide
Mark
Mark
Front brake pipe
Pass the brake pipe
behind the reverse cable.
Pass the brake hose
in front of
the throttle cable.
The white mark faces front side.
White mark White mark
K5
K4
PartShark.com
877-999-5686
PartShark.com
877-999-5686
LT-Z250K6 (06-MODEL) 11-1
CONTENTS
LT-Z250K6 (06-MODEL)
11
This chapter describes specifications, service data and servicing procedures which differ from
those of the LT-Z250K5 (05-MODEL).
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.
SPECIFICATIONS......................................................................................... 11- 2
SERVICE DATA ............................................................................................ 11- 3
PartShark.com
877-999-5686
11-2 LT-Z250K6 (06-MODEL)
SPECIFICATIONS
DIMENSIONS AND DRY MASS
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)
ENGINE
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 cm3 (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, Low .............................................................................. 3.083 (37/12)
2nd............................................................................... 1.933 (29/15)
3rd................................................................................ 1.388 (25/18)
4th................................................................................ 1.095 (23/21)
Top ............................................................................... 0.913 (21/23)
Reverse........................................................................ 2.833 (34/12)
Final reduction ratio............................................................................. 3.200 (32/10)
CHASSIS
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
ELECTRICAL
Ignition type......................................................................................... Electronic ignition (CDI)
Ignition 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 change........................................................................... 190 ml (6.4/6.7 US/Imp oz)
PartShark.com
877-999-5686
LT-Z250K6 (06-MODEL) 11-3
SERVICE DATA
VALVE + GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diam. IN. 32
(1.3)
EX. 28
(1.1)
Tappet clearance (when cold) IN. 0.03  0.08
(0.001  0.003)
EX. 0.08  0.13
(0.003  0.005)
Valve guide to valve stem
clearance IN. 0.010  0.037
(0.0004  0.0015)
EX. 0.030  0.057
(0.0012  0.0024)
Valve stem deflection IN. & EX. 0.35
(0.014)
Valve guide I.D. IN. & EX. 5.500  5.512
(0.2165  0.2170)
Valve stem O.D. IN. 5.475  5.490
(0.2156  0.2161)
EX. 5.455  5.470
(0.2148  0.2154)
Valve stem runout IN. & EX. 0.05
(0.002)
Valve head thickness IN. & EX. 0.5
(0.02)
Valve stem end length IN. & EX. 2.5
(0.10)
Valve seat width IN. & EX. 0.88  1.08
(0.035  0.043)
Valve head radial runout IN. & EX. 0.03
(0.001)
Valve spring free length IN. & EX. 43.0
(1.69)
Valve spring tension IN. & EX. 256  294 N
(26.1  30.0 kgf, 57.5  66.1 lbs)
at length 36.6 mm (1.44 in)
PartShark.com
877-999-5686
11-4 LT-Z250K6 (06-MODEL)
CAMSHAFT + CYLINDER HEAD Unit: mm (in)
CYLINDER + PISTON + PISTON RING Unit: mm (in)
ITEM STANDARD LIMIT
Cam height IN. 33.780  33.820
(1.3299  1.3315) 33.480
(1.3181)
EX. 32.990  33.030
(1.2988  1.3004) 32.690
(1.2870)
Camshaft journal oil clearance 0.036  0.066
(0.0014  0.0026) 0.150
(0.0059)
Camshaft journal holder I.D. 22.012  22.025
(0.8666  0.8671)
Camshaft journal O.D. 21.959  21.976
(0.8645  0.8652)
Camshaft runout 0.10
(0.004)
Rocker arm I.D. IN. & EX. 12.000  12.018
(0.4724  0.4731)
Rocker arm shaft O.D. IN. & EX. 11.977  11.995
(0.4715  0.4722)
Cylinder head distortion 0.05
(0.002)
Cylinder head cover distortion 0.05
(0.002)
ITEM STANDARD LIMIT
Compression pressure 1 400 kPa
(14.0 kgf/cm2, 199 psi)
1 200 kPa
(12.0 kgf/cm2,
171 psi)
Piston to cylinder clearance 0.040  0.050
(0.0016  0.0020) 0.120
(0.0047)
Cylinder bore 66.000  66.015
(2.5984  2.5990) 66.090
(2.6020)
Piston diam. 65.955  65.970
(2.5966  2.5972)
Measure at 18 mm (0.71 in) from the skirt end.
65.880
(2.5937)
Cylinder distortion 0.05
(0.002)
Piston ring free end gap 1st R Approx. 8.7 (0.34) 7.0
(0.28)
2nd R Approx. 9.0 (0.35) 7.2
(0.28)
Piston ring end gap 1st 0.10  0.25
(0.004  0.010) 0.50
(0.020)
2nd 0.10  0.25
(0.004  0.010) 0.50
(0.020)
Piston ring to groove clearance 1st  0.180
(0.007)
2nd  0.150
(0.006)
Piston ring groove width 1st 1.01  1.03
(0.0398  0.0406)
2nd 1.21  1.23
(0.0476  0.0484)
Oil 2.01  2.03
(0.0791  0.0799)
PartShark.com
877-999-5686
LT-Z250K6 (06-MODEL) 11-5
CONROD + CRANKSHAFT Unit: mm (in)
OIL PUMP
CLUTCH Unit: mm (in)
ITEM STANDARD LIMIT
Piston ring thickness 1st 0.97  0.99
(0.038  0.039)
2nd 1.17  1.19
(0.046  0.047)
Piston pin bore 16.002  16.008
(0.6300  0.6302) 16.030
(0.6311)
Piston pin O.D. 15.992  16.000
(0.6296  0.6299) 15.980
(0.6291)
ITEM STANDARD LIMIT
Conrod small end I.D. 16.006  16.014
(0.6302  0.6305) 16.040
(0.6315)
Conrod deflection 3.0
(0.12)
Conrod big end side clearance 0.10  0.45
(0.004  0.018) 1.0
(0.04)
Conrod big end width 17.95  18.00
(0.707  0.709)
Crank web to web width 53.0 – 0.1
(2.087 – 0.004)
Crankshaft runout 0.08
(0.003)
ITEM STANDARD LIMIT
Oil pressure (at 60 C, 140 F) 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
ITEM STANDARD LIMIT
Clutch release screw 1/16  1/8 turn back
Drive plate thickness 2.7  2.9
(0.106  0.114) 2.4
(0.094)
Drive plate claw width 11.9  12.0
(0.469  0.472) 11.0
(0.433)
Driven plate distortion 0.10
(0.004)
Clutch spring free length 28.9
(1.14) 27.5
(1.08)
Clutch wheel I.D. 116.00  116.15
(4.567  4.573) 116.5
(4.59)
Clutch shoe No groove at
any part
Clutch engagement r/min 1 700  2 100 r/min
Clutch lock-up r/min 3 100  3 700 r/min
PartShark.com
877-999-5686
11-6 LT-Z250K6 (06-MODEL)
DRIVE TRAIN Unit: mm (in) Except ratio
CARBRETOR
ITEM STANDARD LIMIT
Primary reduction ratio 3.047 (64/21)
Secondary reduction ratio 1.133 (17/15)
Final reduction ratio 3.200 (32/10)
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)
Shift fork to groove clearance 0.10  0.30
(0.004  0.012) 0.5
(0.020)
Shift fork groove width 4.50  4.60
(0.169  0.173)
Shift fork thickness 4.30  4.40
(0.169  0.173)
Gearshift lever height 0  10
(0  0.393)
Secondary bevel gear backlash 0.03  0.15
(0.001  0.006)
Rear drive (final) bevel gear back-
lash 0.05  0.30
(0.002  0.012)
ITEM SPECIFICATION
E-19, 28 E-33
Carburetor type MIKUNI BSR29 ←
Bore size 29 mm
(1.14 in) ←
I.D. No. 21G0 21G1
Idle r/min 1 500 – 100 r/min ←
Float height 13.0 – 1.0 mm
(0.51 – 0.04 in) ←
Main jet (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 and 1/2 turns back PRE-SET
Throttle cable play 3  5 mm
(0.12  0.20 in) ←
Starter (enricher) plunger cable
play 0.5  1.0 mm
(0.02  0.04 in) ←
PartShark.com
877-999-5686
LT-Z250K6 (06-MODEL) 11-7
ELECTRICAL Unit: mm (in)
WATTAGE Unit: W
ITEM SPECIFICATION NOTE
Spark plug Type NGK: DR7EA
DENSO: X22ESR-U
Gap 0.6  0.7
(0.024  0.028)
Spark performance Over 8 (0.3) at 1 atm.
Ignition coil resistance Primary 0.05  1.0 Ω Terminal 
Terminal
Secondary 10.5  19.0 k Ω Plug cap 
Terminal
Ignition coil primary peak voltage 120 V and more +: B/W -: W/Bl
Generator coil resistance Pick-up 80  155 Ω Bl/Y  G/W
Charging 0.5  1.2 Ω Y  Y
Pick-up coil peak voltage 4.0 V and more +: G/W -: Bl/Y
Generator no-load voltage
(When engine is cold) 65 V (AC) and more at 5 000 r/min
Generator Max. output Approx. 150 W at 5 000 r/min
Regulated voltage 14.0  15.5 V at 5 000 r/min
Starter relay resistance 3  6 Ω
Battery Type designation YTX9-BS
Capacity 12V 28.8 kC (8 Ah)/10HR
Fuse size 20 A
ITEM SPECIFICATION
Headlight HI 40
LO 40
Brake light/Taillight 21/5
Reverse indicator light 3
Neutral indicator light 3
PartShark.com
877-999-5686
11-8 LT-Z250K6 (06-MODEL)
BRAKE + WHEEL Unit: mm (in)
TIRE PRESSURE
VEHICLE LOAD CAPACITY LIMIT: 110 kg (243 lbs)
ITEM STANDARD/SPECIFICATION LIMIT
Rear brake lever play 3  5
(0.12  0.20)
Rear brake pedal free travel 20  30
(0.79  1.18)
Brake disc thickness Front 2.8  3.2
(0.110  0.126) 2.5
(0.098)
Brake disc runout Front  0.30
(0.012)
Brake drum I.D. Rear  140.7
(5.54)
Master cylinder bore Front 12.700  12.743
(0.5000  0.5017)
Master cylinder piston diam. Front 12.657  12.684
(0.4983  0.4994)
Brake caliper cylinder bore Front 32.030  32.080
(1.2610 1.2630)
Brake caliper piston diam. Front 31.948  31.998
(1.2578  1.2598)
Brake fluid type DOT 4
Turning radius 2.7 m (8.9 ft)
Toe-in (with 75 kg, 165 lbs) 5 – 4
(0.20 – 0.16)
Camber 0
Caster 7 40
Wheel rim size Front 10  5.5 AT
Rear 9  8.0 AT
Tire size Front AT22  7-10 ✩✩
Rear AT20  10-9 ✩
Tire tread depth Front  4.0
(0.16)
Rear  4.0
(0.16)
Wheel axle runout Rear  3.0
(0.12)
COLD INFLATION
TIRE PRESSURE kPa kgf/cm2psi
FRONT 30 0.30 4.4
REAR 25 0.25 3.6
PartShark.com
877-999-5686
LT-Z250K6 (06-MODEL) 11-9
FUEL + OIL
ITEM SPECIFICATION NOTE
Fuel type 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.
E-28, 33
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended. The others
Fuel tank capacity including
reserve 10.6 L
(2.8/2.3 US/lmp gal)
Reserve 2.6 L
(0.7/0.6 US/lmp gal)
Engine oil type * SAE 10W-40, API SF/SG or SH/SJ with JASO MA
Engine oil capacity Change 2 200 ml
(2.3/1.9 US/lmp qt)
Filter change 2 300 ml
(2.4/2.0 US/lmp qt)
Overhaul 2 500 ml
(2.6/2.2 US/lmp qt)
Final gear oil type Hypoid gear oil SAE #90, API grade GL-5
Final gear oil capacity 190 ml
(6.4/6.7 US/lmp oz)
PartShark.com
877-999-5686
CONTENTS
NOTE:
LT-Z250K7 (07-MODEL) 12-1
LT-Z250K7 (07-MODEL)
* The specification and service data are the same as the K6-MODEL
12
INFORMATION LABEL INSTALLATION (For E-33) ................................... 12- 2
PartShark.com
877-999-5686
– 2 –
INFORMATION LABEL INSTALLATION (For E-33)
10 ± 5 mm
LABEL
Frame LH side
12- 2 LT-Z250K7 (07-MODEL)
PartShark.com
877-999-5686
CONTENTS
NOTE:
LT-Z250K8 (08-MODEL) 13-1
LT-Z250K8 (08-MODEL)
* The specification and service data are the same as the K7-MODEL
13
INFORMATION LABEL ............................................................................... 13- 2
PartShark.com
877-999-5686
– 2 –
INFORMATION LABELS
* E-28: Fuel caution label enclosed.
E: English
F: French
A: Attached
No. LABEL or PLATE NAME APPLIED SPECIFICATION
E-19 E-28 E-33
1Certification plate
EAA
2Information label
EA
3Gearshift pattern label
EA
4Gearshift pattern label
E/
FA
5Tire air pressure label
EAAA
6Tire air pressure label and warning no-passenger label
FA
7General warning label
EAAA
8General warning label
FA
9Warning no-passenger label
EAAA
0Age, 16 Iabel
EAAA
AAge, 16 Iabel
FA
BManual notice label
EA
CGearshift label
EAAA
DGearshift label
FA
EICES Canada label
E/
F
FCompliance label
EA
GEC approval mark A A
HCompliance label A
Front of left side frame
Left side frame
13-2 LT-Z250K8 (08-MODEL)
PartShark.com
877-999-5686
CONTENTS
6JKUEJCRVGTFGUETKDGUUGTXKEGURGEKHKECVKQPUUGTXKEGFCVCCPFUGTXKEKPIRTQEGFWTGTUYJKEJ
FKHHGTHTQOVJQUGQHVJG.6<-ŏ/1&'.
016'
#P[FKHHGTGPEGUDGVYGGPVJG.6<-ŏ/1&'.CPF.6<-ŏ/1&'.
KPURGEKHKECVKQPUCTGENGCT[KPFKECVGFYKVJCPCUVGTKUMOCTM
2NGCUGTGHGTVQVJGECRVGTUVJTQWIJHQTFGVCKNUYJKEJCTGPQVIKXGPKPVJKUEJCRVGT
PAGE
52'%+(+%#6+105 
5'48+%'&#6#  
(7'.6#0-%105647%6+10  
%#4$74'614  
+0(14/#6+10.#$'.5  
1
LT-Z250K9 (’09 MODEL) 14-1
LT-Z250K9 (’09 MODEL)
14
PartShark.com
877-999-5686
SPECIFICATIONS
DIMENSIONS AND CURB MASS
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)
* Curb mass ........................................................................................ 177 kg (390 lbs)
ENGINE
Type..................................................................................................... 4-stroke, air-cooled, OHC
Number of cylinders ............................................................................ 1
Bore..................................................................................................... 66.0 mm (2.598 in)
Stroke.................................................................................................. 72.0 mm (2.835 in)
Displacement ...................................................................................... 246 cm3 (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-speed forward with reverse
Gearshift pattern, forward.................................................................. All up, foot operated
reverse.................................................................. Foot/hand operated
Primary reduction ratio ........................................................................ 3.047 (64/21)
Gear ratios, Low ................................................................................ 3.083 (37/12)
2nd ................................................................................ 1.933 (29/15)
3rd ................................................................................. 1.388 (25/18)
4th ................................................................................. 1.095 (23/21)
Top................................................................................. 0.913 (21/23)
Reverse ......................................................................... 2.833 (34/12)
Secondary reduction ratio ................................................................... 1.133 (17/15)
Final reduction ratio............................................................................. 3.200 (32/10)
CHASSIS
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’
Trail...................................................................................................... 33 mm (1.30 in)
Toe-in................................................................................................... 5 mm (0.20 in)
Steering angle ..................................................................................... 45° (right & left)
Turning radius...................................................................................... 2.7 m (8.9 ft)
Front brake .......................................................................................... Disc brake, twin
Rear brake........................................................................................... Drum brake
Front tire .............................................................................................. AT22 × 7-10 °°, tubeless
Rear tire .............................................................................................. AT20 × 10- 9 °, tubeless
ELECTRICAL
Ignition type......................................................................................... Electronic ignition (CDI)
Ignition timing ...................................................................................... 5° B.T.D.C. at 1 500 r/min
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 A
Fuse .................................................................................................... 15 A
Headlight ............................................................................................. 12 V 40/40 W
Brake/Tail light ..................................................................................... 12 V 21/5 W
Neutral indicator light........................................................................... 12 V 3 W
Reverse indicator light......................................................................... 12 V 3 W
CAPACITIES
Fuel tank, including reserve ..............................................................* 9.7 L (2.6/2.1 US/Imp gal)
reserve .............................................................................* 2.1 L (0.6/0.5 US/Imp gal)
Engine oil, oil change......................................................................... 2 200 ml (2.3/1.9 US/Imp qt)
with 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........................................................................................ 190 ml (6.4/6.7 US/Imp oz)
14- 2 LT-Z250K9 (09-MODEL)
PartShark.com
877-999-5686
SERVICE DATA
CARBRETOR
FUEL + OIL
ITEM SPECIFICATION
* E-19 * E-28, 33
Carburetor type MIKUNI BSR29 ←
Bore size 29 mm
(1.14 in) ←
I.D. No. 21G0 21G1
Idle r/min 1 500 ± 100 r/min ←
Float height 13.0 ± 1.0 mm
(0.51 ± 0.04 in) ←
Main jet (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 and 1/2 turns back PRE-SET
Throttle cable play 3 – 5 mm
(0.12 – 0.20 in) ←
Starter (enricher) plunger cable
play 0.5 – 1.0 mm
(0.02 – 0.04 in) ←
ITEM SPECIFICATION NOTE
Fuel type 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.
E-28, 33
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended. E-19
Fuel tank capacity including
reserve * 9.7 L
(2.6/2.1 US/lmp gal)
Reserve * 2.1 L
(0.6/0.5 US/lmp gal)
Engine oil type SAE 10W-40, API SF/SG or SH/SJ with JASO MA
Engine oil capacity Change 2 200 ml
(2.3/1.9 US/lmp qt)
Filter change 2 300 ml
(2.4/2.0 US/lmp qt)
Overhaul 2 500 ml
(2.6/2.2 US/lmp qt)
Final gear oil type Hypoid gear oil SAE #90, API grade GL-5
Final gear oil capacity 190 ml
(6.4/6.7 US/lmp oz)
LT-Z250K9 (09 MODEL) 14-3
PartShark.com
877-999-5686
FUEL TANK CONSTRUCTION
1Fuel tank
2Fuel cap
3Breather hose
4Gasket
5Gasket
6Fuel valve
7Fuel hose
14- 4 LT-Z250K9 (09-MODEL)
PartShark.com
877-999-5686
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.
• 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 O-
ring.
1Drill-stop
2Plug
3Pilot screw
4Carburetor 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.
LT-Z250K9 (09 MODEL) 14-5
PartShark.com
877-999-5686
INFORMATION LABELS
Information label (E-28)
Certification label (E-33)
Front of frame right side
FWD
14- 6 LT-Z250K9 (09-MODEL)
PartShark.com
877-999-5686

Navigation menu