Suzuki Gz250 Users Manual

2015-01-26

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FOREWORD

This manual contains an introductory description on

the SUZUKI GZ250 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 fa-

miliarize yourself with the motorcycle 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 motorcycle better so

that you can assure your customers of fast and re-

liable service.

This manual has been prepared on the basis

of the latest specifications at the time of pub-

lication. If modifications have been made

since then, differences may exist between

the content of this manual and the actual mo-

torcycle.

Illustrations in this manual are used to show

the basic principles of operation and work

procedures. They may not represent the ac-

tual motorcycle exactly in detail. This

manual is written for persons who have

enough knowledge, skills and tools, includ-

ing special tools, for servicing SUZUKI mo-

torcycles. If you do not have the proper

knowledge and tools, ask your authorized

SUZUKI motorcycle dealer to help you.

GROUP INDEX

GENERAL INFORMATION

PERIODIC MAINTENANCE

ENGINE

FUEL AND LUBRICATION

SYSTEM

CHASSIS

ELECTRICAL SYSTEM

SERVICING INFORMATION

WARNING

Inexperienced mechanics or mechanics

without the proper tools and equipment

may not be able to properly perform the

service described in this manual. Improp-

er repair may result in injury to the me-

chanic and may render the motorcycle un-

safe for the rider and passenger.

SUZUKI MOTOR CORPORATION

Motorcycle Service Department

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 sec-

tion to help you find the item and page you need.

COMPONENT PARTS AND WORK TO BE DONE

Under the name of each system or unit, is its exploded view. Work instructions and other service

information such as the tightening torque, lubricating points and locking agent points, are provided.

Example: Front wheel

SYMBOL

Listed in the table below are the symbols indicating instructions and other information necessary for

servicing. The meaning of each symbol is also included in the table.

SYMBOL

DEFINITION

SYMBO

L DEFINITION

Torque control required.

Data beside it indicates specified

torque.

Apply THREAD LOCK "1360".

99000-32130

Apply oil. Use engine oil unless

otherwise specified.

Apply or use brake fluid.

Apply molybdenum oil solution (mix-

ture of engine oil and SUZUKI MOLY

PASTE in a ratio of 1 : 1).

Measure in voltage range.

Apply SUZUKI SUPER GREASE

"A".

99000-25010

Measure in resistance range.

Apply SUZUKI SILICONE GREASE.

99000-25100

Measure in current range.

Apply SUZUKI MOLY PASTE.

99000-25140

Measure in diode test range.

Apply SUZUKI BOND "1215".

99000-31110

Measure in continuity test range.

Apply THREAD LOCK SUPER

"1303".

99000-32030

Use special tool.

Apply THREAD LOCK "1342".

99000-32050

Use fork oil. 99000-

99001-SS8

GENERAL INFORMATION

----------------------------------------- CONTENTS ---------------------------------------------- 1

WARNING/CAUTION/NOTE ............................................................... 1- 1

GENERAL PRECAUTIONS ................................................................ 1- 1

SUZUKI GZ250X ('99-MODEL) ........................................................... 1-3

SERIAL NUMBER LOCATION ........................................................... 1-3

FUEL AND OIL RECOMMENDATIONS .............................................. 1-3

FUEL ............................................................................................... 1-3

ENGINE OIL ................................................................................. 1-4

BRAKE FLUID .............................................................................. 1-4

FRONT FORK OIL .......................................................................... 1-4

BREAK-IN PROCEDURES ................................................................. 1-4

INFORMATION LABELS .................................................................... 1-5

SPECIFICATIONS ............................................................................. 1-6

COUNTRY AND AREA CODES ........................................................ 1-8

1-1 GENERAL INFORMATION

WARNING/CAUTION/NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the

symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention

to the messages highlighted by these signal words.

WARNING

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

CAUTION

Indicates a potential hazard that could result in motorcycle damage.

NOTE:

Indicates special information to make maintenance easier or instructions clearer.

Please note, however, that the warnings and cautions contained in this manual cannot possibly cover

all potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the

WARNINGS and CAUTIONS stated, you must use good judgement and basic mechanical safety prin-

ciples. If you are unsure about how to perform a particular service operation, ask a more experienced

mechanic for advice.

GENERAL PRECAUTIONS

WARNING

Proper service and repair procedures are important for the safety of the service me-

chanic and the safety and reliability of the motorcycle.

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

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

outdoors.

When working with toxic or flammable materials, make sure that the area you work in is

well ventilated and that you follow all of the manufacturer's instructions. Never use

gasoline as a cleaning solvent.

To avoid getting burned, do not touch the engine, engine oil and exhaust system until

they have cooled.

After servicing fuel, oil, exhaust or brake systems, check all of the lines and fittings

related to the system for leaks.

GENERAL INFORMATION 1-2

CAUTION

* If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their

equivalent.

* When removing parts that are to be reused, keep them arranged in an orderly manner

so that they may be reinstalled in the proper order.

* Be sure to use special tools when instructed.

* Make sure that all parts used in reassembly are clean. Lubricate them when specified.

* Use the specified 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 cover the positive terminal with the terminal cover.

* When performing service to electrical parts, disconnect the battery negative cable unless

the service procedure requires the battery power.

* When tightening cylinder head and crankcase bolts and nuts, tighten the larger sizes

first. Always tighten the bolts and nuts from the inside working out, in a crisscross

pattern and to the specified tightening torque.

* Whenever you remove oil seals, gaskets, packing, O-rings, self-locking nuts, locking

washers, cotter pins, circlips, and certain other parts as specified, be sure to replace them

with new ones. Also, before installing these new parts, be sure to remove any left over

material from the mating surfaces.

* Never reuse a circlip. When installing a new circlip, take care not to expand the end gap

larger than required to slip the circlip over the shaft. After installing a circlip, always ensure

that it is completely seated in its groove and securely fitted.

* 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.

CAUTION

* To protect the environment, do not unlawfully dispose of used motor oil and all other fluids,

batteries, and tires.

* To protect the earth's natural resouces, properly dispose of used motorcycles and parts.

1-3 GENERAL INFORMATION

SUZUKI GZ250X ('99-MODEL)

SERIAL NUMBER LOCATION

The frame serial number or V.I.N. (Vehicle Identification Number) is stamped on the right side of the

steering head pipe. The engine serial number is located on the left side of the crankcase. These

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

FUEL AND OIL RECOMMENDATIONS

FUEL

Use unleaded gasoline that is graded 91 octane or higher.

GENERAL INFORMATION 1-4

ENGINE OIL

Use only oils which are rated SF or SG under the API clas-

sification. The recommended viscosity is SAE 10W/40. If

SAE 10W/40 engine oil is not available, select an alterna-

tive according to the chart.

BRAKE FLUID

Specification and classification: DOT 4

WARNING

This motorcycle 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 re-use brake fluid left over from a last servicing or which has been stored for a long

period of time.

FRONT FORK OIL

Use SUZUKI fork oil SS-08 (#10).

BREAK-IN PROCEDURES

During manufacturing only the best possible materials are used and all machined parts are finished to

a very high standard. It is still necessary to allow the moving parts to "BREAK-IN" before subjecting the

engine to maximum stresses. The future performance and reliability of the engine depends on the care

and restraint exercised during its early life. The general rules are as follows.

• Keep to this break-in throttle position.

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

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

• Upon reaching an odometer reading of 1 600 km you can subject the motorcycle to full throttle

operation for short periods of time.

GENERAL INFORMATION 1-6

SPECIFICATIONS

DIMENSIONS AND DRY MASS

Overall length .............................................

Overall width ................................................

Overall height ..............................................

Wheelbase ....................................................

Ground clearance .........................................

Seat height ....................................................

Dry mass .....................................................

ENGINE

Type ..............................................................

Number of cylinder ........................................

Bore ...............................................................

Stroke ...........................................................

Displacement ................................................

Compression ratio .........................................

Carburetor ...................................................

Air cleaner .....................................................

Starter system ...............................................

Lubrication system .......................................

TRANSMISSION

Clutch ...........................................................

Transmission ...............................................

Gearshift pattern ............................................

Primary reduction ratio ...............................

Final reduction ratio ......................................

Gear ratios, Low .........................................

2nd ........................................

3rd ..........................................

4th ..........................................

Top .......................................

Drive chain ...................................................

2 160 mm (85.0 in)

815 mm (32.1 in)

1 090 mm (42.9 in)

1 450 mm (57.1 in)

125 mm ( 4.9 in)

680 mm (27.8 in)

137 kg (302 lbs)

Four-stroke, air-cooled, OHC

72.0 mm (2.835 in)

61.2 mm (2.409 in)

249 cm3 (15.2 cu. in)

9.0 : 1

MIKUNI BSR32SS, single

Non-woven fabric element

Electric

Wet sump

Wet multi-plate type

5-speed constant mesh

1-down, 4-up

3.238 (68/21)

2.733 (41/15)

2.636 (29/11)

1.687 (27/16)

1.263 (24/19)

1.000 (20/20)

0.818 (18/22)

DID 520VC5, 110 links

1-7 GENERAL INFORMATION

ELECTRICAL

Ignition type .............................................................. Electronic ignition (Transistorized)

Ignition timing ........................................................ 10° B.T.D.C. at 1 300 r/min

Spark plug .............................................................. NGK DR8EA or DENSO X24ESR-U

Battery ...................................................................... 12V 21.6 kC (6 Ah)/10 HR

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

Fuse ......................................................................... 20/15/15/15/10/10A

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

Position light .......................................................... 12V 4W ....... Except for E-03, -24, -28, -33

Brake light/Taillight .................................................. 12V 21/5W

Front turn signal light/Running light .......................... 12V 21/5W ....... E-03, -28, -33

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

Speedometer light .................................................... 12V 1.7W

Neutral indicator light ................................................ 12V 3.4W

Turn signal indicator light ......................................... 12V 3.4W

High beam indicator light ........................................ 12V 1.7W

CHASSIS

Front suspension ................................................... Telescopic, coil spring, oil damped

Rear suspension ...................................................... Swingarm type, coil spring, oil damped, spring

preload 5-way adjustable

Front fork stroke ....................................................... 120 mm (4.7 in)

Rear wheel travel ..................................................... 90 mm (3.5 in)

Steering angle .......................................................... 40° (right and left)

Caster ...................................................................... 32° 30'

Trail ......................................................................... 140 mm (5.5 in)

Turning radius .......................................................... 2.6 m (8.5 ft)

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

Rear brake ................................................................ Internal expanding

Front tire size .......................................................... 110/90-16 59P

Rear tire size ............................................................ 130/90-15M/C 66P

CAPACITIES

Fuel tank, including reserve ..................................... 14 L (3.7/3.1 US/Imp gal)

reserve ................................................ 2.9 L (0.8/0.6 US/Imp gal)

Engine oil, oil change ........................................... 1 300 ml (1.4/1.1 US/Imp qt)

with filter change ................................ 1 400 ml (1.5/1.2 US/Imp qt)

overhaul ............................................. 1 700 ml (1.8/1.5 US/Imp qt)

Front fork oil (each leg) ......................................... 369 ml (12.5/13.0 US/Imp oz)

Specifications are subject to change without notice.

GENERAL INFORMATION 1-8

COUNTRY AND AREA CODES

The following codes stand for the applicable country(-ies) and area(-s).

CODE

COUNTRY OR AREA

E-01

General

E-02

E-03

U.S.A. (Except for California)

E-04

France

E-17

Sweden, Finland (E-15), Norway (E-16), Denmark (E-26)

E-22

Germany

E-24

Australia

E-25

Netherlands

E-28

Canada

E-33

California (U.S.A.)

E-34

Italy, Belgium (E-21), Spain (E-53)

PERIODIC MAINTENANCE

----------------------------------------- CONTENTS ------------------------------------------

PERIODIC MAINTENANCE SCHEDULE ............................................. 2- 1

PERIODIC MAINTENANCE CHART ................................................ 2- 1

LUBRICATION POINTS ................................................................. 2-2

MAINTENANCE AND TUNE-UP PROCEDURES .............................. 2-3

EXHAUST PIPE BOLTS AND MUFFLER MOUNTING BOLTS ......... 2-3

AIR CLEANER ................................................................................ 2- 3

VALVE CLEARANCE ..................................................................... 2-4

SPARK PLUG ................................................................................. 2- 6

FUEL HOSE .................................................................................... 2- 7

ENGINE IDLE SPEED ..................................................................... 2- 7

THROTTLE CABLE PLAY ............................................................... 2- 7

STARTER PLUNGER CABLE PLAY ............................................... 2-9

CLUTCH .......................................................................................... 2-9

ENGINE OIL AND OIL FILTER ........................................................ 2- 9

DRIVE CHAIN .................................................................................. 2-70

BRAKES .......................................................................................... 2-12

TIRE ............................................................................................... 2-15

STEERING ....................................................................................... 2-15

FRONT FORK ................................................................................. 2-16

REAR SUSPENSION ....................................................................... 2-16

CHASSIS BOLTS AND NUTS ......................................................... 2-16

COMPRESSION PRESSURE CHECK ............................................... 2-18

OIL PRESSURE CHECK .................................................................... 2-19

2-1 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

The chart below lists the recommended intervals for all the required periodic service work necessary to

keep the motorcycle operating at peak performance and economy. Maintenance intervals are ex-

pressed in terms of kilometers and months, and are dependant on whichever comes first.

NOTE:

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

PERIODIC MAINTENANCE CHART

Interval

Item

1 000

5 000

10 000

15 000

miles

600

3 000

6 000

9 500

months

Exhaust pipe bolts and muffler mounting

bolts

Air cleaner element

Clean every 3 000 km (2 000 miles).

Valve clearance

Spark plug

Fuel hose

Replace every 4 years.

Engine idle speed

Throttle cable play

Clutch

Engine oil

Engine oil filter

Drive chain

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

Brakes

Brake hose

Replace every 4 years.

Brake fluid

Replace every 2 years.

Tires

Steering

Front fork

Rear suspension

Chassis bolts and nuts

NOTE:

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

C: Clean R: Replace T: Tighten

PERIODIC MAINTENANCE 2-2

LUBRICATION POINTS

Proper lubrication is important for smooth operation and long life of each working part of the motor-

cycle. Major lubrication points are indicated below.

Side-stand pivot Drive chain

and spring hook

Brake pedal pivot

NOTE:

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

* Lubricate exposed parts which are subject to rust, with a rust preventative spray especially whenever

the motorcycle has been operated under wet or rainy condition.

Clutch lever holder

Brake lever holder

2-3 PERIODIC MAINTENANCE

MAINTENANCE AND TUNE-UP PROCEDURES

This section describes the servicing procedures for each

item in the Periodic Maintenance chart.

EXHAUST PIPE BOLTS AND MUFFLER

MOUNTING BOLTS

Tighten every 5 000 km (3 000 miles, 15 months).

• Tighten the exhaust pipe bolts and muffler mounting

bolt to the specified torque.

Exhaust pipe bolt : 14 N ■ m (1.4 kg-m, 10.0 Ib-ft)

Muffler mounting bolt : 29 N ■ m (2.9 kg-m, 21.0 Ib-ft)

AIR CLEANER

Clean every 3 000 km (2 000 miles).

If the air cleaner is clogged with dust, intake resistance will

increase, resulting in a decrease in engine output and an

increase in fuel consumption. Check and clean the air

cleaner element in the following manner.

• Remove the front seat. (See p. 5-1.)

• Remove the left frame cover. (See p. 5-1.)

• Remove the air cleaner element .

PERIODIC MAINTENANCE 2-4

• Carefully use compressed air to clean the air cleaner

element.

CAUTION ________________________________

Always apply compressed air to the

outside of the air cleaner element. If compressed

air is applied to the inside, dirt will be forced into

the pores of the air cleaner element, restricting

air flow through the air cleaner element.

• Reinstall the cleaned or new air cleaner element in the

reverse order of removal.

• When installing the air cleaner element into the air clean-

er case, align the triangle marks on the air cleaner ele-

ment and the air cleaner case.

CAUTION

If driving under dusty conditions, clean the air

cleaner element more frequently. The surest way

to accelerate engine wear is to operate the engine

without the element or to use a torn element.

Make sure that the air cleaner is in good condition

at all times. The life of the engine depends largely

on this component!

NOTE:

When cleaning the air cleaner element, remove the plug

and drain any water from the air cleaner drain hose.

VALVE CLEARANCE

Inspect initially at 1 000 km (600 miles, 3 months)

and every 5 000 km (3 000 miles, 15 months) there-

after.

INSPECTION

• Remove the front seat. (See p. 5-1.)

• Remove the fuel tank. (See p. 4-1.)

• Remove the cylinder head cover left cap

• Disconnect the spark plug cap and remove the spark

plug.

09930-10121: Spark plug socket wrench set

CAUTION

2-5 PERIODIC MAINTENANCE

Remove the valve inspection caps

The valve clearance specification is different for intake and

exhaust valves.

Valve clearance adjustment must be checked and adjusted,

1) at the time of periodic inspection, 2) when the valve

mechanism is serviced, and 3) when the camshaft is re-

moved for servicing.

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)

NOTE:

* The piston must be at top dead center (TDC) on the

compression stroke in order to check or adjust the valve

clearance.

* The valve clearance should only be checked when the

engine is cold.

* Remove the valve timing inspection plug and

generator cover cap

Rotate the crankshaft with a box wrench to set the piston

at top dead center (TDC) on the compression stroke.

(Rotate the crankshaft until the "T" line on the

generator rotor is aligned with the triangle mark on

the generator cover.)

Insert a thickness gauge into the clearance between the

valve stem end and the adjusting screw on the rocker

arm.

09900-20803: Thickness gauge

If the clearance is out of specification, adjust it to specifica-

tion as follows.

PERIODIC MAINTENANCE 2-6

ADJUSTMENT

The clearance is adjusted using the special tool and offset

wrench.

• Loosen the locknuts

• Insert a thickness gauge between the valve stem end

and the adjusting screw on the rocker arm.

• Adjust the valve clearance by turning the adjusting screw

using the special tool while holding the locknuts

09917-14920: Valve adjuster wrench

CAUTION

Both the right and left valve clearances should be as

closely as possible.

• After the adjustment is completed, tighten the locknut se-

curely.

• Rotate the crankshaft 720° with a box wrench and check

that the clearance is within specification.

SPARK PLUG

Inspect every 5 000 km (3 000 miles, 15 months).

Replace every 10 000 km (6 000 miles, 30 months).

Neglecting the spark plug eventually leads to difficult start-

ing and poor engine performance. If the spark plug is used

for a long period, the electrode gradually bums away and

carbon builds up along the inside part of the spark plug. In

accordance with the Periodic Maintenance chart, the spark

plug should be inspected, cleaned and regapped at the rec-

ommended intervals.

• Remove the cylinder head cover left cap.

• Disconnect the spark plug cap and remove the spark

plug.

09930-10121: Spark plug socket wrench set

• Carbon deposits on the spark plug will prevent

good

sparking and may cause the engine to misfire. Be sure to

clean the carbon deposits off periodically.

If the center electrode is fairly worn down, the spark plug

should be replaced and the spark plug gap set to the speci-

fication using a thickness gauge.

09900-20803: Thickness gauge

Spark plug gap: 0.6-0.7 mm (0.024-0.028 in)

2-7 PERIODIC MAINTENANCE

Check the spark plug for burns. If any abnormalities are

found, replace the spark plug as indicated below.

NGK

DENSO

Remarks

DR7EA

X22ESR-U

If the standard spark plug is

apt to get wet, replace with

this plug.

DR8EA

X24ESR-U

Standard

DR9EA

X27ESR-U

If the standard spark plug is

apt to overheat, replace with

this plug.

CAUTION

Confirm the thread size and reach when replacing

the spark plug. If the reach is too short, carbon

will be deposited on the screw portion of the plug

hole and engine damage may result.

CAUTION

Before using a spark plug wrench, carefully turn

the spark plug by finger into the threads of the

cylinder head to prevent damage.

• Tighten the spark plug to the specified torque using the

special tool.

Spark plug: 18 N-m (1.8 kg-m, 13.0 Ib-ft)

09930-10121: Spark plug socket wrench set

FUEL HOSE

Inspect every 5 000 km (3 000 miles, 15 months).

Replace every 4 years.

ENGINE IDLE SPEED

Inspect initially at 1 000 km (600 miles, 3 months)

and every 5 000 km (3 000 miles, 15 months) there-

after.

• Adjust the throttle cable play. (See p. 2-8.)

• Warm up the engine.

NOTE:

Make this adjustment when the engine is hot.

• Connect an electric tachometer to the high tension cord.

PERIODIC MAINTENANCE 2-8

• Start the engine, turn the throttle stop screw and set

the engine idle speed as follows.

Engine idle speed:

1 300 ± 50 r/min .... For E-03, -28, -33

1 300 ±100 r/min ..... For the others

09900-26006: Tachometer

THROTTLE CABLE PLAY

Inspect initially at 1 000 km (600 miles, 3 months)

and every 5 000 km (3 000 miles, 15 months) there-

after.

Adjust the throttle cable play

steps.

First step:

• Loosen the lock nut of the throttle returning cable

and turn in the adjuster fully into the threads.

Second step:

• Loosen the lock nut of the throttle pulling cable

• Turn the adjuster in or out until the throttle cable play

should be 2.0-4.0 mm (0.08-0.16 in) at the throttle

grip.

• Tighten the lock nut while holding the adjuster

Third step:

• While holding the throttle grip at the fully closed position,

slowly turn out the adjuster of the throttle returning

cable to feel resistance.

• Tighten the lock nut while holding the adjuster

Throttle cable play : 2.0-4.0 mm (0.08-0.16 in)

WARNING

After the adjustment is completed, check that

handlebar movement does not raise the engine

idle speed and that the throttle grip returns

smoothly and automatically.

NOTE:

Major adjustment can be made by the carburetor side ad-

juster.

with the following three

2-9 PERIODIC MAINTENANCE

STARTER PLUNGER CABLE PLAY

Starter plunger cable play should be 0.5-1.0 mm

(0.02-0.04 in) as shown. If the play is incorrect, adjust

it as follows:

• Loosen the lock nut and turn the adjuster in or out

until the specified play is obtained.

• Tighten the lock nut while holding the adjuster

Starter plunger cable play

CLUTCH

Inspect every 5 000 km (3 000 miles, 15 months).

• Loosen the lock nut and turn the adjuster fully in.

• Loosen the lock nut and turn the adjuster until the

clutch lever play is within specification.

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

• Tighten the lock nuts

ENGINE OIL AND OIL FILTER

(ENGINE OIL)

Replace initially at 1 000 km (600 miles, 3 months)

and every 5 000 km (3 000 miles, 15 months) there-

after.

(OIL FILTER)

Replace initially at 1 000 km (600 miles, 3 months)

and every 10 000 km (6 000 miles, 30 months)

thereafter.

The engine oil should be changed while the engine is

warm. Oil filter replacement at the above intervals should

be done together with the engine oil change.

ENGINE OIL REPLACEMENT

• Keep the motorcycle upright.

• Place an oil pan below the engine, and drain the engine

oil by removing the engine oil drain plug and oil filler

cap .

• Tighten the oil drain plug to the specified torque, and

pour new oil through the oil filler. When performing an oil

change (without oil filter replacement), the engine will

hold about 1 300 ml (1.4/1.1 US/Imp qt) of oil. Use SF or

SG classified (API) engine oil with a viscosity rating of

10W-40 (SAE).

Oil drain plug: 28 N-m (2.8 kg-m, 20.0 Ib-ft)

• Install the oil filler cap

0.5-1.0 mm

(0.02-0.04 in)

PERIODIC MAINTENANCE 2-10

• Start up the engine and allow it to run for a few minutes

at idling speed.

• Turn off the engine and wait about one minute, then

check the oil level through the inspection window . If

the level is below the "F" mark, add oil to the proper

level.

OIL FILTER REPLACEMENT

• Drain the engine oil as described in the engine oil re-

placement procedure.

• Remove the oil filter cap by removing the nuts.

• Remove the oil filter and install a new one.

• Install the oil filter cap and tighten the nuts securely.

NOTE:

Before installing the new oil filter and oil filter cap, make

sure that the spring and new O-rings are

installed correctly.

• Add new engine oil and check the oil level as described

in the engine oil replacement procedure.

Oil viscosity and classification:

10W/40 (SAE)/SF or SG (API)

NECESSARY AMOUNT OF ENGINE OIL

Oil change : 1 300 ml (1.4/1.1 US/Imp qt)

Oil and filter change: 1 400 ml (1.5/1.2 US/Imp qt)

Engine overhaul : 1 700 ml (1.8/1.5 US/Imp qt)

DRIVE CHAIN

Inspect initially at 1 000 km (600 miles, 3 months)

and every 5 000 km (3 000 miles, 15 months) there-

after. Clean and lubricate every 1 000 km (600

miles).

Visually inspect the drive chain for the possible defects

listed below. (Support the motorcycle by a jack and a

wooden block, turn the rear wheel slowly by hand with the

transmission shifted to Neutral.)

• Loose pins * Excessive wear

• Damaged rollers * Kinked or binding links

• Dry or rusted links * Missing O-ring seals

• Twisted or seized links

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

CAUTION __________________________________

The standard drive chain is DID520VC5. SUZUKI

recommends to use this standard drive chain as a

The standard drive chain is DID520VC5. SUZUKI

recommends to use this standard drive chain as a

replacement.

2-11 PERIODIC MAINTENANCE

CHECKING AND ADJUSTING

• Remove the rear axle cotter pin. (For E-28 model)

• Loosen the rear axle nut

• Tense the drive chain fully by turning chain adjuster nuts

• Count out 21 pins (20-pitch) on the chain measure the

distance between the two points. If the distance exceeds

the service limit, the chain must be replaced.

Drive chain 20-pitch length: 319.4 mm (12.57 in)

NOTE:

When replacing the drive chain, replace the drive chain and

sprockets as a set.

• Place the motorcycle on the side-stand.

• Loosen both chain adjuster nuts until the chain has 5-15

mm (0.2-0.6 in) of slack at the middle of the chain between

the engine and rear sprockets as shown. The reference

marks must be at the same position on the scale to

ensure that the front and rear wheels are correctly aligned.

Drive chain slack: 5-15 mm (0.2-0.6 in)

• After adjusting the drive chain, tighten the rear axle nut

to the specified torque.

Rear axle nut:

65 N-m (6.5 kg-m, 47.0 Ib-ft) ........ For E-03, -28, -33

78 N-m (7.8 kg-m, 56.5 Ib-ft) ........ For the others

• Recheck the chain slack after tightening the axle nut and

readjust if necessary.

* Tighten both chain adjuster nuts securely.

• Install the new cotter pin. (For E-03, -28, -33 models)

CLEANING AND LUBRICATING

• Clean the drive chain with kerosine. If the drive chain

tends to rust quickly, the intervals must be shortened.

CAUTION

Do not use trichloroethylene, gasoline or any sim-

ilar solvent.

These fluids have too great a dissolving power for

this chain and they can damage the O-rings. Use

only kerosine to clean the drive chain.

PERIODIC MAINTENANCE 2-12

• After cleaning and drying the chain, oil it with a heavy-

weight engine oil.

CAUTION

Do not use any oil sold commercially as "drive

chain oil", this type of oil can such oil can damage

the "0"-rings (or seals).

BRAKES

(BRAKE)

Inspect initially at 1 000 km (600 miles, 3 months)

and every 5 000 km (3 000 miles, 15 months) there-

after.

(BRAKE HOSE AND BRAKE FLUID)

Inspect every 5 000 km (3 000 miles, 15 months).

Replace hose every 4 years. Replace fluid every 2

years.

BRAKE FLUID LEVEL

• Keep the motorcycle upright and place the handlebars

straight.

• Check the brake fluid level by observing the lower limit

line on the front brake fluid reservoir.

• When the brake fluid level is below the lower limit line

replenish with brake fluid that meets the following specifi-

cation.

Specification and classification: DOT 4

WARNING

The brake system of this motorcycle is filled

with a glycol-based brake fluid. Do not use or

mix different types of fluid such as silicone-

based and petroleum-based fluids. Do not use

any brake fluid taken from old, used or un-

sealed containers. Never re-use 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 sur-

faces. Check the brake hose and hose joints for

cracks and oil leakage.

2-13 PERIODIC MAINTENANCE

FRONT BRAKE PADS

The extent of brake pad wear can be checked by observing

the limit line on the pad. When the wear exceeds the

limit line, replace the pads with new ones. (See p. 5-8.)

A CAUTION

Replace the brake pad as a set, otherwise braking

performance will be adversely affected.

AIR BLEEDING THE BRAKE FLUID CIRCUIT

Air trapped in the brake fluid circuit acts like a cushion to

absorb a large proportion of the pressure developed by the

master cylinder and thus interferes with the full braking per-

formance of the brake caliper. The presence of air is indi-

cated by "sponginess" of the brake lever and also by lack

of braking force. Considering the danger to which such

trapped air exposes the machine and rider, it is essential

that, after remounting the brake and restoring the brake

system to the normal condition, the brake fluid circuit be

purged of air in the following manner:

• Fill the master cylinder reservoir to top of the inspection

window. 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.

• Bleed air from the brake system.

• Squeeze and release the brake lever several times in

rapid succession and squeeze the lever fully without re-

leasing it. Loosen the bleeder valve by turning it a quar-

ter of a turn so that the brake fluid runs into the recep-

tacle, this will remove the tension of the brake lever

causing it to touch the handlebar grip. Then, close the air

bleeder valve, pump and squeeze the brake lever, and

open the valve. Repeat this process until the fluid flowing

into the receptacle no longer contains air bubbles.

NOTE:

While bleeding the brake system, replenish the brake fluid

in the reservoir as necessary. Make sure that there is al-

ways some fluid visible in the reservoir.

• Close the air bleeder valve, and disconnect the hose. Fill

the reservoir with brake fluid to the top of the inspection

window.

Air bleeder valve: 7.5 N ■ m (0.75 kg-m, 5.5 Ib-ft)

A CAUTION

Handle brake fluid with care: the fluid reacts

chemically with paint, plastics, rubber materials,

etc.

PERIODIC MAINTENANCE 2-14

REAR BRAKE PEDAL HEIGHT

• Loosen the lock nut

• Adjust the brake pedal height by turning the adjuster

to locate the pedal 50 mm (2.0 in) above the top face

of the footrest.

REAR BRAKE ADJUSTING

• Adjust the free travel to 20-30 mm (0.8-1.2 in) by

turning the adjusting nut

REAR BRAKE SHOE WEAR

This motorcycle is equipped with brake lining wear limit

indicator on the rear brake.

To check brake lining wear, perform the following steps.

• Make sure that the rear brake is properly adjusted.

• Depress the rear brake pedal. Make sure that the index

mark is within the range embossed on the brake

panel.

• If the index mark goes beyond the range, the brake shoe

assembly should be replaced with a new set of shoes.

The extension line of the index mark is within

the range.

The extension line of the index mark is out of

the ranae.

BRAKE LIGHT SWITCH

Adjust the rear brake light switch so that the brake light will

come on just before pressure is felt when the brake pedal

is depressed.

2-15 PERIODIC MAINTENANCE

TIRE

Inspect every 5 000 km (3 000 miles, 15 months).

TIRE TREAD CONDITION

Operating the motorcycle with excessively worn tires will

decrease riding stability and consequently invite a danger-

ous situation. It is highly recommended to replace a tire

when the remaining depth of tire tread reaches the follow-

ing specification.

Tire tread depth limit (front): 1.6 mm (0.06 in)

(rear) : 2.0 mm (0.08 in)

09900-20805: Tire depth gauge

TIRE PRESSURE

If the tire pressure is too high or too low, steering will be

adversely affected and tire wear increased. Therefore,

maintain the correct tire pressure for good roadability and a

longer tire life. Cold inflation tire pressure is as follows.

COLD INFLATION

TIRE PRESSURE

SOLO RIDING

DUAL RIDING

kPa

kg/cm2

psi

kPa

kg/cm2

psi

FRONT

175

1.75

175

1.75

REAR

200

2.00

225

2.25

CAUTION

The standard tire fitted on this motorcycle is a

110/90-16 59P for the front and a 130/90-15M/C 66P

for the rear. The use of tires other than those speci-

fied may cause instability. It is highly recommended

to use the specified tires.

STEERING

Inspect initially at 1 000 km (600 miles, 3 months)

and every 10 000 km (6 000 miles, 30 months)

thereafter.

The steering should be adjusted properly for smooth turning

of handlebars and safe operation. Overtight steering prevents

smooth turning of the handlebars and too loose steering will

cause poor stability. Check that there is no play in the front

fork. Support the motorcycle so that the front wheel is off the

ground. With the wheel facing straight ahead, grasp the lower

fork tubes near the axle and pull forward. If play is found, read-

just the steering. (See p. 5-27.)

PERIODIC MAINTENANCE 2-16

FRONT FORK

Inspect every 10 000 km (6 000 miles, 30 months).

Inspect the front forks for oil leakage, scoring or scratches

on the outer surface of the inner tubes. Replace any defec-

tive parts, if necessary.

REAR SUSPENSION

Inspect every 10 000 km (6 000 miles, 30 months).

Inspect the rear shock absorber for oil leakage and damage.

Replace any defective parts, if necessary.

CHASSIS BOLTS AND NUTS

Tighten initially at 1 000 km (600 miles, 3 months)

and every 5 000 km (3 000 miles, 15 months) there-

after.

Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-17 for the

locations of the following nuts and bolts on the motorcycle.)

ITEM

N-m

kg-m

Ib-ft

Handlebar clamp bolt

1.6

11.5

Handlebar holder nut

4.5

32.5

Steering stem head bolt

6.5

47.0

Front fork upper clamp bolt

2.3

16.5

Front fork lower clamp bolt

3.3

24.0

Front fork cap bolt

2.3

16.5

Front fork damper rod bolt

2.3

16.5

Front axle

6.5

47.0

Front axle pinch bolt

2.3

16.5

Front brake caliper mounting bolt

3.9

28.0

Front brake hose union bolt

2.3

16.5

Front brake caliper air bleeder valve

7.5

0.75

5.5

Front brake master cylinder mounting bolt

1.0

7.0

Front brake disc bolt

2.3

16.5

Front brake pad mounting bolt

1.8

13.0

Front footrest bolt

2.6

19.0

Swingarm pivot nut

7.2

52.0

Rear axle nut

For E-03, -28, -33

6.5

47.0

For the others

7.8

56.5

Rear torque link nut (front and rear)

1.3

9.5

Rear shock absorber mounting bolt or nut

2.9

21.0

Rear sprocket nut

5.0

36.0

Rear brake cam lever bolt

1.0

7.0

Spoke nipple

4.5

0.45

3.5

2-17 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-18

COMPRESSION PRESSURE CHECK

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

decision to overhaul the cylinder is often based on the results of a compression test. Periodic

maintenance records kept at your dealership should include compression readings for each mainte-

nance service. COMPRESSION PRESSURE SPECIFICATION

Standard

Limit

1 000-1 400 kPa

10.0-14.0 kg/cm2

142-199 psi

800 kPa 8

kg/cm2

114 psi

Low compression pressure can indicate any of the following conditions:

* Excessively worn cylinder wall

* Worn piston or piston rings

* Piston rings stuck in grooves

* Poor valve seating

* Ruptured or otherwise defective cylinder head gasket

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 valves are properly ad

justed.

• Have the engine warmed-up before testing.

" Make sure that the battery is fully-charged.

Remove the related parts and test the compression pres-

sure in the following manner.

• Install the compression gauge and adaptor in the spark

plug hole. Make sure that the connection is tight.

• Keep the throttle grip in the fully opened position.

• Press the starter button and crank the engine for a few

seconds. Record the maximum gauge reading as the

cylinder compression.

09915-64510: Compression gauge

09918-03810: Adaptor

2-19 PERIODIC MAINTENANCE

OIL PRESSURE CHECK

Check the oil pressure periodically. This will give a good indication of the condition of the moving parts. OIL

PRESSURE SPECIFICATION

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

Below 70 kPa (0.7 kg/cm2, 10.0 psi) at 3 000 r/min., Oil temp, at 60°C (140°F)

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

LOW OIL PRESSURE

* 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

Check the oil pressure in the following manner.

o Install the oil pressure gauge in the position shown.

• Connect an electric tachometer.

• Warm up the engine as follows:

Summer 10 min. at 2 000 r/min.

Winter 20 min. at 2 000 r/min.

• After warm up, increase the engine speed to 3 000 r/min.

and read the oil pressure gauge.

09915-74510: Oil pressure gauge

ENGINE

i ------------------------------------------------ CONTENTS ---------------------------------

ENGINE COMPONENTS REMOVABLE WITH THE ENGINE

IN PLACE ......................................................................................................

.... 3- 1

ENGINE REMOVAL AND REINSTALLATION ............................................

ENGINE REMOVAL .................................................................................

3- 2 .... 3-

ENGINE REINSTALLATION .................................................................

ENGINE DISASSEMBLY ......................................................................

3- 6 .... 3-

ENGINE COMPONENTS INSPECTION AND SERVICE ......................

.... 3-19

CRANKCASE BEARINGS ..................................................................

__ 3-19

CLUTCH RELEASE CAMSHAFT .......................................................

__ 3-22

CYLINDER HEAD COVER ..................................................................

.... 3-23

CYLINDER HEAD ..............................................................................

.... 3-24

CAM CHAIN GUIDE AND CAM CHAIN TENSIONER ......................

__ 3-32

CAMSHAFT .........................................................................................

__ 3-32

CAM CHAIN TENSION ADJUSTER ...................................................

__ 3-34

CYLINDER ...........................................................................................

__ 3-34

PISTON AND PISTON PIN ..................................................................

__ 3-34

CRANKSHAFT AND CONROD ...........................................................

__ 3-37

BALANCER SHAFT AND BALANCER SHAFT DRIVEN GEAR

STARTER CLUTCH AND STARTER DRIVEN GEAR BEARING

GENERATOR STATOR AND PICK-UP COIL .....................................

3-39

3-40

__ 3-41

TRANSMISSION ................................................................................

__ 3-42

PRIMARY DRIVEN GEAR ...................................................................

__ 3-44

CLUTCH ...............................................................................................

__ 3-45

CLUTCH COVER .................................................................................

__ 3-46

OIL FILTER ..........................................................................................

.... 3-46

OIL SUMP FILTER ...............................................................................

.... 3-47

ENGINE REASSEMBLY .........................................................................

.... 3-48

CRANKSHAFT ....................................................................................

.... 3-48

BALANCER SHAFT ............................................................................

.... 3-48

TRANSMISSION ................................................................................

.... 3-48

GEARSHIFT CAM AND GEARSHIFT FORKS ....................................

.... 3-49

CRANKCASE .....................................................................................

.... 3-50

GENERATOR ROTOR .......................................................................

__ 3-52

DRIVESHAFT RETAINER .................................................................

__ 3-52

PRIMARY DRIVE GEAR .....................................................................

.... 3-52

BALANCER SHAFT BOLT .................................................................

.... 3-53

GEARSHIFT CAM DRIVEN GEAR .....................................................

.... 3-53

OIL PUMP ............................................................................................

.... 3-54

CLUTCH ..............................................................................................

.... 3-55

CLUTCH COVER .................................................................................

__ 3-57

STARTER IDLE GEAR ........................................................................

__ 3-57

GENERATOR COVER .........................................................................

__ 3-57

NEUTRAL SWITCH .............................................................................

__ 3-58

ENGINE SPROCKET SPACER ...........................................................

__ 3-58

STARTER MOTOR ..............................................................................

.... 3-58

PISTON AND PISTON RING ...............................................................

.... 3-59

CYLINDER ...........................................................................................

.... 3-60

CYLINDER HEAD ..............................................................................

.... 3-61

CAMSHAFT .........................................................................................

__ 3-62

CAM CHAIN TENSION ADJUSTER ....................................................

__ 3-63

CYLINDER HEAD COVER ..................................................................

.... 3-64

3-1 ENGINE

ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN

PLACE

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

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

ENGINE CENTER

See page

Exhaust pipe and muffler ............ 3-2 and -8

Carburetor .................................. 3-4 and -7

Cam chain tension adjuster ... 3-9 and -63

Cylinder head cover ..................... 3-9 and -64

Camshaft .................................. 3-10 and -62

Cylinder head ............................ 3-10 and -61

Cylinder ........................................ 3-10 and -60

Piston ........................................ 3-11 and -59

Starter motor ................................ 3-11 and -58

Oil sump filter ............................. 3-47

ENGINE LEFT SIDE ENGINE RIGHT SIDE

See page See page

Gearshift link arm ........................ 3-2 Oil filter .......................................... 3-46

Engine sprocket cover ................. 3-3 Clutch cover .................................. 3-12 and -57

Engine sprocket ......................... 3-3 and -7 Clutch .......................................... 3-12 and -55

Generator cover ......................... 3-12 and -57 Oil pump ....................................... 3-14 and -54

Generator rotor ............................ 3-16 and -52 Gearshift shaft .............................. 3-14 and -54

Starter idle gear .......................... 3-16 and -57 Primary drive gear ....................... 3-15 and -52

Generator stator ......................... 3-41

Pick-up coil .................................. 3-41

Neutral switch ............................. 3-11 and -58

ENGINE 3-2

ENGINE REMOVAL AND

REINSTALLATION

ENGINE REMOVAL

• Remove the front seat. (See p. 5-1.)

• Remove the fuel tank. (See p. 4-1.)

• Remove the right frame cover. (See p. 5-1.)

• Disconnect the battery lead wire.

• Drain the engine oil. (See p. 2-9.)

• Remove the right footrest bracket.

• Remove the exhaust pipe bolts.

• Remove the exhaust pipe by removing the bolt

• Remove the muffler mounting bolt

• Remove the gearshift link arm.

3-3 ENGINE

• Remove the engine sprocket cover.

• Flatten the lock washer.

• Remove the engine sprocket nut and washer.

NOTE:

When loosening the engine sprocket nut, temporarily install

the right footrest bracket and depress the brake pedal.

• Remove the engine sprocket.

NOTE:

If it is difficult to remove the engine sprocket, loosen the

rear axle nut and chain adjuster nuts to provide additional

chain slack.

• Remove the clutch release arm .

• Loosen the clutch cable adjuster lock nut and remove

the clutch cable.

• Remove the left and right cylinder head cover caps.

• Disconnect the spark plug cap.

ENGINE 3-4

• Remove the starter plunger .

• Loosen the carburetor clamp screws.

• Remove the carburetor.

¿WARNING

Gasoline is very explosive. Extreme care must be

taken.

• Disconnect the engine ground wire.

• Disconnect the crankcase breather hose

• Disconnect the starter motor lead wire.

• Disconnect the side-stand switch coupler

• Disconnect the generator couplers

• Disconnect the neutral switch coupler

3-5 ENGINE

• Support the motorcycle with a jack or wooden block.

• Remove the engine mounting bolts and nuts

• Remove the frame down tube mounting bolts and nuts

• Remove the lower engine mounting bolt and nut

• Remove the upper engine mounting bolt and nut

NOTE:

When removing the upper mounting bolt, support the en-

gine with a jack.

• Remove the left and right swingarm pivot end caps.

• Remove the swingarm pivot nut and washer.

• Partially remove the swingarm pivot shaft so that the

engine can be removed.

NOTE:

Be careful not to draw out the pivot shaft.

• Gradually lower the engine.

ENGINE 3-6

ENGINE REINSTALLATION

Reinstall the engine in the reverse order of engine removal.

• Install the engine mounting bolts and nuts as shown in the following illustration.

• Tighten the engine mounting nuts to the specified torque.

NOTE:

The engine mounting nuts are self-locking. Once the nuts have been removed, they are no longer of

any use.

ITEM

N-m

kg-m

Ib-ft

4.1

29.5

4.1

29.5

4.1

29.5

BOLT LENGTH

50 mm (2.0 in)

67 mm (2.6 in)

100 mm (3.9 in)

• Tighten the swingarm pivot nut to the specified torque.

Swingarm pivot nut: 72 N-m (7.2 kg-m, 52.0 Ib-ft)

• Tighten the frame down tube mounting bolts and nuts to

the specified torque.

Frame down tube mounting bolt/nut: 23 N-m

(2.3 kg-m, 16.5 Ib-ft)

NOTE;

Apply a small quantity of THREAD LOCK "1303" to the

threads of bolts.

99000-32030: THREAD LOCK SUPER "1303"

3-7 ENGINE

• Tighten the engine ground wire and the clamp by crank-

case bolt as shown.

• Clamp the neutral switch lead wire and side-stand

switch lead wire

• Position the carburetor clamps as shown in the illustra-

tion.

• Install the clutch release arm as shown In the illustration.

NOTE:

Align the release arm slit surface with the notch mark

on the release camshaft.

• Loosen the rear axle nut and drive chain adjuster nuts.

• Install the engine sprocket as shown.

• Install the drive chain.

• Tighten the engine sprocket nut to the specified

torque.

Engine sprocket nut: 90 N-m (9.0 kg-m, 65.0 Ib-ft)

NOTE:

When tightening the engine sprocket nut, depress the rear

brake pedal.

• Bend the lock washer securely.

ENGINE 3-8

• Tighten the exhaust pipe bolts and muffler mounting bolt

to the specified torque.

Exhaust pipe bolt: 14 N-m (1.4 kg-m, 10.0 Ib-ft)

Muffler mounting bolt: 29 N-m (2.9 kg-m, 21.0 Ib-ft)

CAUTION

Check the wire, cable and hose routing.

(See pp. 7-11 to -18.)

• Install the right footrest and tighten its mounting bolts to

the specified torque.

Front footrest bolt: 26 N-m (2.6 kg-m, 19.0 Ib-ft)

• After remounting the engine, the following adjustments

are necessary.

* Engine idling speed ............................... See p. 2-7.

* Throttle cable play ................................. See p. 2-8.

* Starter plunger cable play .................... See p. 2-9.

* Clutch lever play ................................. See p. 2-9.

* Drive chain slack ................................. See p. 2-11.

* Rear brake pedal height and

free travel ............................................ See p. 2-14.

• Pour 1 700 ml (1.8/1.5 US/Imp qt) of SAE 10W/40 en

gine oil, graded SF or SG, into the engine after overhaul

ing it. Start up the engine and allow it run for several

minutes at idle speed. Stop the engine, wait a few min

utes and check the oil level. If the level is below the "L"

line, add oil until the level reaches the "F" line. (See pp.

2-9 and -10.)

3-9 ENGINE

ENGINE DISASSEMBLY

The procedure for engine disassembly is sequentially ex-

plained in the following steps.

• Remove the valve inspection caps

• Remove the spark plug.

• Remove the valve timing inspection plug and generator

cover cap.

• Rotate the crankshaft and align the "T" line on the

generator rotor with the mark on the generator cover.

• Remove the cylinder head cover

NOTE:

If the cylinder head cover does not come off, lightly tap on

the finless portion of it with a plastic mallet to make the

gasketed joint loose.

• Remove the rubber cap and then turn the slotted

end of cam chain tension adjuster with the flat-head

screwdriver in the clockwise direction and lock the

push rod.

• Remove the cam chain tension adjuster by

removing the mounting bolts.

• Remove the camshaft end cap

• Flatten the lock washer and remove the camshaft

sprocket bolts.

ENGINE 3-10

• Remove the camshaft and camshaft sprocket .

CAUTION

Do not drop the cam chain into the crankcase.

• Remove the C-ring

CAUTION

Do not drop the C-ring into the crankcase.

• Remove the cylinder head nuts diagonally.

• Remove the cylinder head by removing the cylinder

head nuts

NOTE:

If the cylinder head does not come off, lightly tap on the

finless portion of it with a plastic mallet.

• Remove the cylinder head gasket and dowel pins.

• Remove the cam chain guide

• Remove the cylinder by removing the nuts.

NOTE:

If the cylinder does not come off, lightly tap on the Unless

portion of it with a plastic mallet to make the gasketed joint

loose.

3-11 ENGINE

• Remove the cylinder gasket and dowel pins.

• Place a clean rag over the cylinder base to prevent the

piston pin circlip from dropping into the crankcase.

Then, remove the piston pin circlip with a long-nose

pliers.

• Remove the piston pin using the special tool.

09910-34510: Piston pin puller

• Remove the piston.

• Remove the starter motor

• Flatten the lock portion of the oil seal retainer

• Remove the oil seal retainer .

• Remove the spacer

• Remove the neutral switch

• Remove the neutral switch contact , spring and O-

ring

ENGINE 3-12

• Remove the generator cover.

• Remove the gasket and dowel pins.

• Remove the clutch cover.

• Remove the gasket and dowel pins.

• While holding the generator rotor using the special tool,

remove the clutch spring mounting bolts in a crisscross

pattern, and remove the clutch springs and clutch pres-

sure plate

09930-44913: Rotor holder

3-13 ENGINE

• Remove the washer , bearing , clutch push piece

and clutch push rod

• Remove the clutch drive and driven plates.

• Remove the spring washer and washer seat

• Flatten the lock washer of the clutch sleeve hub nut.

• Remove the clutch sleeve hub nut using the special tool.

09920-53740: Clutch sleeve hub holder

• Remove the clutch sleeve hub

ENGINE 3-14

• Remove the thrust washer and primary driven gear

assembly

• Remove the spacer and thrust washer

• Remove the círclíp and oil pump driven gear

• Remove the pin and washer .

• Remove the oil pump

A CAUTION

Do not attempt to disassemble the oil pump as-

sembly.

• Remove the gearshift shaft

• Remove the pawl lifter and cam guide by removing

the screws.

• Remove the gearshift cam driven gear

NOTE:

When removing the cam driven gear , do not lose the

pawls , pins and springs .

• Remove the gearshift shaft stopper

3-15 ENGINE

• While holding the generator rotor using the special tool,

remove the balancer shaft bolt

09930-44913: Rotor holder

• Remove the cam chain

• Remove the primary drive gear nut using the special

tool.

09930-44913: Rotor holder

A CAUTION

The primary drive gear nut has left-hand threads.

• Remove the spring washer

• Remove the primary drive gear

• Remove the keys

• Remove the cam chain sprocket

• Remove the circlip and washer

ENGINE 3-16

• Remove the shaft and starter idle gear

• Remove the generator rotor nut using the special tool.

09930-44913: Rotor holder

• Remove the generator rotor using the special tool.

09930-34960: Rotor remover

• Remove the generator rotor key

• Remove the starter driven gear

• Remove the bearing and washer

3-17 ENGINE

• Remove the gearshift cam stopper.

• Remove the crankcase bolts.

• Separate the left and right crankcases using the special

tool.

09920-13120: Crankcase separator

NOTE:

* Fit the crankcase separator, so that the tool arms are in

parallel with the side of crankcase.

* The crankshaft and transmission components should re-

main in the left crankcase half.

* When separating the crankcase, tap the end of the coun-

tershaft with a plastic mallet.

* Remove the O-ring

• Remove the shim , washer and balancer shaft driv-

en gear

• Remove the washer

ENGINE 3-18

• Remove the gearshift cam stopper spring

• Remove the gearshift fork shafts and gearshift forks

• Remove the gearshift cam

• Remove the transmission.

• Remove the balancer shaft

• Remove the balancer shaft drive gear

• Remove the crankshaft using the special tool.

09920-13120: Crankcase separator

3-19 ENGINE

ENGINE COMPONENTS

INSPECTION AND SERVICE

CRANKCASE BEARINGS

BEARING INSPECTION

While the bearing is in the crankcase, rotate its inner race

and check to see that it turns smoothly. If it does not turn

quietly and smoothly, or if there are signs of any abnormali-

ties, the bearing is defective and must be replaced as fol-

lows.

BEARING REMOVAL

• Remove the bearing retainers

NOTE:

Remove the driveshaft bearing retainer along with the

driveshaft bearing

• Remove the oil seals using the special tool.

09913-50121: Oil seal remover

CAUTION

The removed oil seals should be replaced with

new ones.

Remove the bearings.

CAUTION

The removed bearings should be replaced with

new ones.

ENGINE 3-20

• Remove the oil seal using the special tool.

09913-75510: Bearing remover/installer

A CAUTION

The removed oil seal should be replaced with a

new one.

BEARING INSTALLATION

• Install the bearings using the special tools.

09913-75510: Bearing remover/installer (For )

09913-75520: Bearing remover/installer (For , )

09913-75830: Bearing remover/installer (For )

09913-84510: Bearing remover/installer (For )

09913-85210: Bearing remover/installer (For )

• Install the oil seal into the left crankcase using the

special tool.

09913-85210: Bearing remover/installer

• Apply grease to the oil seal lip.

99000-25010: SUZUKI SUPER GREASE "A"

• Place the washer so that the convex of it faces

towards the oil seal.

3-21 ENGINE

• Install the left crankcase bearing using the special tool

and suitable attachment (used beanng e.g.).

09913-75510: Bearing remover/installer

• Install the washer

• Install the left drlveshaft bearing with the bearing retainer

• Install the bearing retainers

NOTE:

Apply a small quantity of THREAD LOCK "1342" to the

bearing retainer screws.

99000-32050: THREAD LOCK "1342"

• Apply grease to the oil seal lip 99000-

25010: SUZUKI SUPER GREASE "A"

• Install the driveshaft oil seals as shown.

CAUTION

When installing the oil seal , Do not block the oil

passage.

ENGINE 3-22

CLUTCH RELEASE CAMSHAFT

REMOVAL

• Remove the oil seal retainer and clutch cable guide

• Remove the oil seal

• Remove the clutch release cam shaft

REASSEMBLY

• Apply engine oil to the clutch release camshaft as

shown in the illustration.

• Install the clutch release camshaft , washer and oil

seal

3-23 ENGINE

CYLINDER HEAD COVER

CAUTION

Identify the position of each removed part. Organize

the parts in their respective groups (i.e., intake or

exhaust) so that they can be installed in their original

locations.

DISASSEMBLY

• Remove the rocker arm shaft bolts

• Remove the rocker arm shafts

• Remove the rocker arms and wave washers

CYLINDER HEAD COVER DISTORTION

After removing the sealant (SUZUKI BOND "1215") from the

mating surface of the cylinder head cover, place the cylinder

head cover on a surface plate and check for distortion with a

thickness gauge. Check points are shown in Fig.

09900-20803: Thickness gauge

Service Limit: 0.05 mm (0.002 in)

If the distortion exceeds the limit, replace the cylinder head

cover.

ROCKER ARM SHAFT O.D.

Measure the diameter of the rocker arm shafts.

09900-20205: Micrometer (0-25 mm)

Standard (IN. & EX.):

11.966-11.984 mm (0.4711-0.4718 in)

ROCKER ARM I.D.

Measure the inside diameter of the rocker arm and check the

wear of the camshaft contacting surface.

09900-20605: Dial calipers

Standard (IN. & EX.):

12.000-12.018 mm (0.4724-0.4731 in)

ENGINE 3-24

REASSEMBLY

Reassemble the cylinder head cover in the reverse order of

disassembly. Pay attention to the following points: •

Apply engine oil to the rocker arm shafts.

• Install the rocker arms , wave washers and

shafts

[ A CAUTION]

Use the new O-rings to prevent oil leakage.

• Tighten the rocker arm shaft bolts to the specified

torque.

Rocker arm shaft bolt: 10 Nm (1.0 kg-m, 7.0 Ib-ft)

CYLINDER HEAD

I A CAUTION |

Identify the position of each removed part. Orga-

nize the parts in their respective groups (i.e., in-

take or exhaust) so that they can be installed in

their original locations.

DISASSEMBLY

• Remove the cam chain tensioner

• Remove the intake pipe

3-25 ENGINE

• Compress the valve spring using the special

tools.

09916-14510: Valve lifter 09916-14910:

Valve lifter attachment

• Remove the valve cotters from the valve stem.

09916-84511: Tweezers

• Remove the valve spring retainer and valve spring

• Remove the valve from the combustion chamber side.

• Remove the valve stem seal

• Remove the valve spring seat

ENGINE 3-26

CYLINDER HEAD DISTORTION

Decarbon the combustion chamber. Check the gasket surface

of the cylinder head for distortion using a straightedge and

thickness gauge. Take clearance readings at several places.

If readings exceed the service limit, replace the cylinder head.

09900-20803: Thickness gauge

Service Limit: 0.05 mm (0.002 in)

VALVE FACE WEAR

The thickness of the valve face decreases as the face wears.

Visually inspect each valve face for wear and replace any

valve with an abnormally worn face. Measure the valve face

thickness , if it is out of specification, replace the valve with

a new one.

09900-20101: Vernier calipers

Service Limit: 0.5 mm (0.02 in)

VALVE STEM RUNOUT

Support the valve using V-blocks, as shown, and measure its

runout with the dial gauge. If the runout exceeds the limit,

replace the valve.

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

09900-20701: Magnetic stand 09900-

21304: V-block (100 mm)

Service Limit: 0.05 mm (0.002 in)

VALVE HEAD RADIAL RUNOUT

Place the dial gauge at a right angle to the valve head face

and measure the valve head radial runout.

If it measures more than the service limit, replace the

valve.

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

09900-20701: Magnetic stand 09900-21304:

V-block (100 mm)

Service Limit: 0.03 mm (0.001 in)

VALVE STEM DEFLECTION

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

Measure the valve stem deflection in two directions, "X" and

"Y", perpendicular to each other. Position the dial gauge as

shown. If the deflection exceeds the service limit, then

determine whether the valve or the guide should be replaced

with a new one.

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

20701: Magnetic stand

Service Limit

Intake and exhaust valves: 0.35 mm (0.014 in)

3-27 ENGINE

VALVE STEM WEAR

Measure the valve stem O.D. using the micrometer. If it is out

of specification, replace the valve with a new one. If the valve

stem O.D. is within specification but the valve stem deflection

is not, replace the valve guide. After replacing the valve or

valve guide, re-check the deflection.

09900-20205: Micrometer (0-25 mm)

Standard

Valve stem O.D.

IN.: 5.460-5.475 mm (0.2150-0.2156 in)

EX.: 5.445-5.460 mm (0.2144-0.2150 in)

NOTE:

If valve guides have to be replaced, refer to the valve guide

servicing steps below.

VALVE GUIDE SERVICE

* Remove the valve guide using the special tool.

09916-44910: Valve guide remover/installer

NOTE:

* Discard the removed valve guide subassemblies.

* Only oversized valve guides are available as replace-

ment parts.

• Re-finish the valve guide holes in the cylinder head using

the special tools.

09916-34561: Valve guide reamer (11.3 mm)

09916-34542: Handle

NOTE:

Insert the reamer from the combustion chamber side and

always turn the reamer handle clockwise.

• Install a ring onto each valve guide.

• Oil the stem hole of each valve guide and drive the guide

into the guide hole using the special tool.

09916-44910: Valve guide remover/installer

A CAUTION

Be sure to use a new valve guide ring and valve guide.

ENGINE 3-28

• After installing the valve guides, re-finish their guiding

bores using the special tools. Be sure to clean and oil

the guides after reaming.

09916-34550: Valve guide reamer (5.5 mm)

09916-34542: Handle

VALVE SEAT WIDTH

• Coat the valve seat uniformly with Prussian blue. Install

the valve and attach a 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.

• The ring-like dye impression left on the valve face must

be continuous without any breaks. In addition, the width

of the dye ring, which is the valve seat width, must be

within the following specification:

Standard

Valve seat width : 0.9-1.1 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 both intake and exhaust valves are ma-

chined to two different angles. (The seat contact surface is

cut 45°.)

INTAKE SIDE

EXHAUST SIDE

45°

N-122

45°

N-122

15°

N-121

15°

N-121

09916-21111: Valve seat cutter set

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

09916-20620: Valve seat cutter (N-122)

09916-24450: Solid pilot (N-100-5.52)

NOTE:

The valve seat contact area must be inspected after each

cut.

3-29 ENGINE

• When installing the solid pilot , rotate it slightly. Seat

the pilot snugly. Install the 45° cutter, attachment and

T-handle.

• Using the 45° cutter, descale and clean up the seat. Ro-

tate the cutter one or two turns.

• Measure the valve seat width after every cut. If the valve

seat is pitted or burned, use the 45° cutter to condition

the seat same more.

NOTE:

Cut only the minimum amount necessary from the seat to

prevent the possibility of the valve stem becoming too

close to the rocker arm for correct valve contact angle.

If the contact area is too high on the valve, or If it is too

wide, use the 15° cutter to lower and narrow the contact

area.

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

cutter to raise and widen the contact area.

• After the desired seat position and width is achieved, use

the 45° cutter very lightly to clean up any burrs caused

by the previous cutting operations.

CAUTION

Contact area too high and too wide

on face of valve

DO NOT use lapping compound after the final cut

is made. The finished valve seat should have a

velvety smooth finish and not a highly polished or

shiny finish. This will provide a soft surface for

the final seating of the valve which will occur dur-

ing the first few seconds of engine operation.

Clean and assemble the head and valve components.

Fill the intake and exhaust ports with gasoline to check

for leaks. If any leaks occur, inspect the valve seat and

face for burrs or other things that could prevent the valve

from sealing.

WARNING

Always use extreme caution when handling gaso-

line.

NOTE:

After servicing the valve seats, be sure to check the valve

clearance after the cylinder has been reinstalled. (See pp.

2-4 to -6.)

Contact area too low and too narrow on face of valve

ENGINE 3-30

VALVE SPRINGS

Check the valve springs for proper strength by measuring

their free length and also the force required to compress

them. If the spring length is less than the service limit or if

the force required to compress the spring does not fall with-

in the specified range, replace the spring.

Service Limit

Valve spring free length (IN. & EX.): 40.1 mm (1.58 in)

Standard

Valve spring tension (IN. & EX.): 18.4-21.6 kg/35.0 mm

(40.56-47.62 lbs/1.38 in)

18.4-21.6 kg

(40.56-47.62 lbs)

REASSEMBLY

Reassemble the cylinder head in the reverse order of dis-

assembly. Pay attention to the following points: • Install

each valve spring seat .

• Apply molybdenum oil solution to the valve stem seal,

and press-fit the seal into position by hand.

A CAUTION

Do not reuse the valve stem seals.

09900-20201: Vernier calipers

35.0 mm

(1.38 in)

3-31 ENGINE

• Apply molybdenum oil solution to the valve stems.

CAUTION

When inserting each valve, take care not to dam-

age the lip of the stem seal.

• Install the valve springs with the smaller pitch facing

the cylinder head.

• Install the valve spring retainer , press down the spring

using the valve lifter and then install the cotter halves

onto the valve stem end. Then, release the valve lifter to

allow the cotter to wedge between the retainer and

the valve stem. Be sure that the rounded lip of the

cotter fits snugly into the groove in the stem end.

09916-14510: Valve lifter 09916-14910:

Valve lifter attachment 09916-84511:

Tweezers

CAUTION

Be sure to install all of the parts in their original

positions.

INTAKE PIPE

• When installing the intake pipe, apply grease to the CD-

ring.

99000-25010: SUZUKI SUPER GREASE "A"

CAUTION

Use the new O-ring to prevent sucking air from

the joint.

Towards

Head

ENGINE 3-32

NOTE:

Make sure that the "UP" mark comes upward.

CAM CHAIN GUIDE AND CAM CHAIN

TENSIONER

Check the cam chain guide and cam chain tensioner for

wear and damage. If it is found to be damaged, replace it

with a new one.

CAMSHAFT

CAMSHAFT INSPECTION

If the engine produces abnormal noises, vibration or lacks

power, a camshaft may be distorted or worn to the service

limit. The camshaft runout should be checked. Also, check

the cams and journals for wear or damage.

CAM WEAR

Worn-down cams are often the cause of mistimed valve

operation resulting in reduced power output. Measure the

cam height using the micrometer. Replace a camshaft if

the cams are worn to the service limit.

09900-20202: Micrometer (25-50 mm)

Service Limit

Cam height (IN.) : 34.690 mm (1.3657 in)

(EX.) : 34.730 mm (1.3673 in)

CAMSHAFT JOURNAL WEAR

Determine whether or not each journal is worn down to the

limit by measuring the oil clearance with the camshaft

installed in place. Measure the clearance using the plasti-

gauge .

09900-22301: Plastigauge

09900-22302: Plastigauge

3-33 ENGINE

NOTE:

Install the cylinder head cover to its original position.

Tighten the cylinder head cover bolts evenly and diagonally

to the specified torque.

Cylinder head cover bolt: 10 N ■ m (1.0 kg-m, 7.0 Ib-ft)

NOTE:

Do not rotate the camshaft with the plastigauge in place.

Remove the cylinder head cover and measure the width of the

compressed plastigauge using the envelope scale. This

measurement should be taken at the widest part of the

compressed plastigauge.

Service Limit

Camshaft-Journal oil clearance: 0.150 mm

(0.0059 in)

If the camshaft journal oil clearance exceeds the limit,

measure the inside diameter of the camshaft journal holder

and outside diameter of the camshaft journal. Replace the

camshaft or the cylinder head depending upon which one

exceeds the specification.

09900-22403: Small bore gauge

Standard

Camshaft journal holder I.D.

(Right side) : 25.012-25.025 mm (0.9847-0.9852 in)

(Left side) : 20.012-20.025 mm (0.7879-0.7884 in)

09900-20205: Micrometer (0-25 mm)

Standard

Camshaft journal O.D.

(Right side) : 24.959-24.980 mm (0.9826-0.9835 in)

(Left side) : 19.959-19.980 mm (0.7858-0.7866 in)

CAMSHAFT RUNOUT

Measure the runout using a dial gauge. Replace the camshaft

if the runout exceeds the limit.

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

09900-20701: Magnetic stand 09900-21304:

V-block set (100 mm)

Service Limit

Camshaft runout: 0.10 mm (0.004 in)

ENGINE 3-34

CAM CHAIN TENSION ADJUSTER

The cam chain tension adjuster is maintained at the proper

tension by an automatically adjusted tensioner. Insert a flat-

head screwdriver into the slotted end of the cam chain ten-

sion adjuster and turn it clockwise to release the tension.

Remove the screwdriver to make sure that the push rod

moves properly. If the push rod is stuck or the spring mech-

anism does not work, replace the cam chain tension adjust-

er assembly with a new one.

CYLINDER

DISTORTION

Check the gasket surface of the cylinder for distortion using

a straightedge and thickness gauge. Take clearance read-

ings at several places. If any reading exceeds the service

limit, replace the cylinder.

09900-20803: Thickness

gauge Service Limit: 0.05 mm (0.002

in)

CYLINDER BORE

Measure the cylinder bore diameter at six places. If any

one of the measurements exceed the limit, overhaul the

cylinder and replace the piston with an oversize piston, or

replace the cylinder.

PISTON AND PISTON PIN

DIAMETER

Measure the piston diameter using the micrometer at 15

mm (0.6 in) from the skirt end.

If the piston diameter is less than the service limit, replace

the piston.

09900-20203: Micrometer (50-75 mm)

Service Limit: 71.880 mm (2.8299

in) Piston oversize: 0.5, 1.0 mm

PISTON-CYLINDER CLEARANCE

Subtract the piston diameter from the cylinder bore diame-

ter. If the piston-to-cylinder clearance exceeds the service

limit, rebore the cylinder and use an oversize piston or re-

place both the cylinder and the piston.

Service Limit: 0.120 mm (0.0047 in)

09900-20508: Cylinder gauge set

Service Limit: 72.085 mm (2.8380 in)

3-35 ENGINE

PISTON RING-GROOVE CLEARANCE

Measure the side clearance of the 1st and 2nd rings using

the thickness gauge If any of the clearances exceed the

limit, replace both the piston and piston rings.

09900-20803: Thickness gauge 09900-

20205: Micrometer (0-25 mm)

Service Limit

Piston ring-groove clearance 1st: 0.180 mm

(0.0071 in)

2nd: 0.150 mm

(0.0059 in)

Standard

Piston ring groove width

1st: 1.01-1.03 mm

(0.040-0.041 in)

2nd: 1.21-1.23 mm

(0.047-0.048 in)

Oil: 2.51-2.53 mm

(0.099-0.100 in)

Standard

Piston ring thickness

1st: 0.975-0.990 mm

(0.0384-0.0390 in)

2nd: 1.170-1.190 mm

(0.0461-0.0469 in)

NOTE:

Remove any carbon from the piston crown and ring

grooves using a soft-metal scraper.

PISTON RING FREE END GAP AND PISTON RING END

GAP

Measure the piston ring free end gap using a vernier calipers.

Next, fit the piston ring squarely into the cylinder and measure

the piston ring end gap using a thickness gauge. If the piston

ring's end gap is out of specification, replace the piston ring.

09900-20101: Vernier calipers

Service Limit

Piston ring free end gap 1st: 7.6 mm (0.30 in)

2nd: 8.8 mm (0.35 in)

09900-20803: Thickness gauge

Service Limit

Piston ring end gap (1st and 2nd): 0.50 mm (0.020 in)

ENGINE 3-36

OVERSIZE RINGS

Oversize piston ring

The following oversize piston ring is used. It bears the fol-

lowing identification number.

Piston ring 1st and 2nd 0.5 mm: 50

1.0 mm: 100

Oversize oil ring

The following oversize oil ring is used. It bears the follow-

ing Identification mark.

Oil ring 0.5 mm: Painted blue 1.0

mm: Painted yellow

Oversize side rail

Measure the outside diameter to identify the side.

0.5mmO.S

I.OmmO.S.

Oil ring

spacer

PIN BORE

Measure the piston pin bore inside diameter using the cali-

per gauge and measure the piston pin outside diameter

using the micrometer. If either is out of specification or the

difference between these two measurements is more than

the limits, replace both piston and piston pin.

09900-20605: Dial calipers 09900-

20205: Micrometer (0-25 mm)

Service Limit

Piston pin bore: 18.030 mm (0.7098 in)

Piston pin O.D.: 17.980 mm (0.7079 in)

3-37 ENGINE

CRANKSHAFT AND CONROD

Crankshaft,

Conrod

Bearing

Crank pin

Crankshaft,

CONROD SMALL END I.D.

Measure the conrod small end inside diameter using the

dial calipers. If the conrod small end inside diameter ex-

ceeds the service limit, replace the conrod.

09900-20605: Dial calipers

Service Limit: 18.040 mm (0.7102 in)

ENGINE 3-38

CONROD DEFLECTION AND CONROD BIG END SIDE

CLEARANCE

Wear on the big end of the conrod can be estimated by

checking the movement of the small end of the rod. This

method can also check the extent of wear on the parts of the

conrod's big end.

09900-20701: Magnetic stand 09900-20606:

Dial gauge (1/100 mm) 09900-21304: V-

block set (100 mm)

Service Limit: 3.0 mm (0.12 in)

Push the big end of the conrod to one side and measure the

side clearance using a thickness gauge.

09900-20803: Thickness gauge

Standard: 0.10-0.65 mm (0.004-0.026 in) Service

Limit: 1.0 mm (0.04 in)

If the service limit is exceeded, replace crankshaft assembly

or bring the deflection and side clearance into specification by

replacing the worn parts, (e.g., conrod, big end bearing and

crank pin)

CRANKSHAFT RUNOUT

Support the crankshaft with V-blocks as shown. Position

the dial gauge, as shown, and rotate the crankshaft slowly

to read the runout. Correct the runout or replace the crank-

shaft assembly if the runout is greater than the service lim-

it.

09900-20701: Magnetic stand 09900-

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

21304: V-block set (100 mm)

Service Limit: 0.05 mm (0.002 in)

REASSEMBLY

• When rebuilding the crankshaft, the width between the

webs should be within the standard range.

Standard width between webs : 60.0 + 0.1 mm

(2.362 ±0.004 in)

3-39 ENGINE

BALANCER SHAFT AND BALANCER SHAFT DRIVEN GEAR

DISASSEMBLY

• Disassemble the balancer shaft as shown in the illustration.

Balancer shaft

Key

Balancer shaft driven

gear

Spring (6 pcs.)

Pin (3 pcs.)

INSPECTION

Inspect the balancer shaft and balancer shaft driven gear

for wear or damage. If any wear or damage is found, re-

place the defective part.

Measure the free length of each balancer spring using ver-

nier calipers. If any spring is not within the service limit,

replace all of the spring.

09900-20101: Vernier calipers

Service Limit: 10.0 mm (0.39 in)

REASSEMBLY

Reassemble the balancer shaft driven gear in the reverse

order of disassembly. Pay attention to the following points:

• Make sure that the punch mark on the inner race is

aligned with the punch mark on the balancer shaft

driven gear.

: Pin

ENGINE 3-40

STARTER CLUTCH AND STARTER DRIVEN GEAR BEARING

1 Starter driven gear

2 Starter clutch

3 Roller

4 Push piece

5 Spring

STARTER CLUTCH

Install the starter driven gear onto the starter clutch and turn

the starter driven gear by hand (the gear turns in only one

direction). The starter driven gear should turn smoothly. If

excessive resistance is felt while turning the starter driven

gear, inspect the starter clutch. Also, inspect the surface of the

starter driven gear which contacts the starter clutch, for wear

or damage. If any wear or damage is found, replace the

defective part(-s).

STARTER DRIVEN GEAR BEARING

Install the starter driven gear bearing and gear onto

the crankshaft and turn the starter driven gear by hand.

Inspect the starter driven gear bearing for smooth rotation

and any abnormal noise. If the bearing does not turn

smoothly or there is any abnormal noise, replace it.

DISASSEMBLY

• Remove the starter driven gear.

• Remove the roller , spring and push piece

3-41 ENGINE

• Hold the generator rotor with the rotor holder and re-

move the starter clutch bolts.

09930-44913: Rotor holder

REASSEMBLY

• Locate the shim to the proper position.

• Apply a small quantity of THREAD LOCK SUPER "1303" to

the starter clutch bolts and tighten them to the specified

torque while holding the rotor holder.

99000-32030: THREAD LOCK SUPER "1303"

09930-44913: Rotor holder Starter clutch

bolt: 18 N-m (1.8 kg-m, 13.0 Ib-ft)

GENERATOR STATOR AND PICK-UP

COIL

When replacing the generator stator or pick-up coil

apply THREAD LOCK "1342" to the generator stator set

bolts and pick-up coil set bolts and tighten them.

99000-32050: THREAD LOCK "1342"

ENGINE 3-42

TRANSMISSION

DISASSEMBLY

• Disassemble the transmission gears as shown in the illustration.

REASSEMBLY

Assemble the countershaft and driveshaft in the reverse order of disassembly. Pay attention to the

following points.

NOTE:

Before installing the gears, apply engine oil to the bearing and inner surface of the each gear.

CAUTION ___________________________________________________________________

* Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded

and a new circlip must be installed.

* When installing a new circlip, do not expand the end gap larger than required to slip the

circlip over the shaft.

* After installing a circlip, make sure that it is completely seated in its groove and securely

fitted.

1 1st driven gear 2

5th driven gear 3

3rd driven gear 4 4th

driven gear 5 2nd

driven gear 6

Driveshaft 7

Countershaft 8 5th

drive gear 9 3rd

drive gear 10 4th

drive gear 11 2nd

drive gear

3-43 ENGINE

When installing a new circlip, pay attention to the direc-

tion of the circlip. Fit the circlip to the side where the

thrust is as shown in the illustration. The rounded side

should be against the gear surface.

Thrust

Sharp edge

Washers and circlips thickness

1.2 mm (0.05 in) 1.0 mm

(0.04 in) 1.0 mm (0.04 in)

1.0 mm (0.04 in) 2.0 mm

(0.08 in) 0.5 mm (0.02 in)

ENGINE 3-44

GEARSHIFT FORKS

Measure the gearshift fork clearance in the groove of its

respective gear using the thickness gauge. The clearance for

each of the two gearshift forks plays an important role in the

smoothness and positiveness of the shifting action. Each fork

has its prongs fitted into the annular groove provided in its

gear. During operation there is sliding contact between the

fork and gear and, when a shifting action is initiated, the fork

pushes the gear axially. If the clearance is too great, the

meshed gears may slip apart.

If the clearance exceeds the specification, replace the fork, its

respective gear or both.

09900-20803: Thickness gauge

Service Limit

Gearshift fork to groove clearance: 0.60 mm (0.024 in)

Standard

Gearshift fork groove width No.1, No.2 & No.3: 4.25-4.35

mm (0.167-0.171 in)

Standard

Shift fork thickness No.1, No.2 & No.3: 3.95-4.05 mm

(0.156-0.159 in)

PRIMARY DRIVEN GEAR

• Remove the stopper ring

• Remove the oil pump drive gear

If the internal damper wears, play is generated between

gear and housing, causing abnormal noise. If the play is

extreme, replace the primary driven gear assembly with a

new one.

Primary driven gear

Damper

Clutch housing

3-45 ENGINE

CLUTCH

CLUTCH DRIVE PLATES

Measure the thickness and claw width of the clutch drive

plates using vernier calipers. If a clutch drive plate is not

within the service limit, replace the clutch plates as a set.

09900-20101: Vernier calipers

Service Limit

Thickness (No.1): 2.62 mm (0.103 in)

(No.2): 3.15 mm (0.124 in) Claw width:

15.0 mm (0.590 in)

CLUTCH DRIVEN PLATES

Measure each clutch driven plates for distortion using the

thickness gauge. If a clutch driven plate is not within the

service limit, replace the clutch plates as a set.

09900-20803: Thickness gauge

Service Limit: 0.10 mm (0.004 in)

CLUTCH SPRING FREE LENGTH

Measure the free length of each clutch spring using vernier

calipers. If any spring is not within the service limit, replace

all of the spring.

09900-20101: Vernier

calipers Service Limit: 40.9 mm (1.61

in)

CLUTCH RELEASE BEARING

Inspect the clutch release bearing for any abnormality, es-

pecially cracks. When removing the bearing from the

clutch, decide whether it can be reused or if it should be

replaced.

Smooth engagement and disengagement of the clutch de-

pends on the condition of this bearing.

ENGINE 3-46

CLUTCH COVER

• Remove the oil seal retainer

• Remove the oil seal using the special tool.

09913-50121: Oil seal remover

• Install the new oil seal using a suitable socket

• Install the oil seal retainer.

NOTE:

Apply a small quantity of THREAD LOCK "1342" to the oil

seal retainer screws.

99000-32050: THREAD LOCK "1342"

OIL FILTER

• Remove the oil filter cap

• Remove the oil filter and install a new one.

NOTE:

Before installing the new oil filter and oil filter cap, make

sure that the spring and new O-rings are

installed correctly.

• Install the oil filter cap.

3-47 ENGINE

OIL SUMP FILTER

• Remove the oil sump filter cap

• Remove the oil sump filter

INSPECTION

Check the oil sump filter for any damage or clogs.

CLEANING

Clean the oil sump filter with a compressed air.

ENGINE 3-48

ENGINE REASSEMBLY

Reassemble the engine in the reverse order of disassembly. The following steps require special atten-

tion or precautionary measures should be taken.

NOTE:

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

CRANKSHAFT

• When installing the crankshaft into the crankcase, it is

necessary to pull its left end into the left crankcase with

the special tools.

09910-32812: Crankshaft installer

09910-32840: Attachment 09910-

20116: Conrod holder

CAUTION

Never install the crankshaft into the crankcase by

striking it with a plastic hammer. Always use the spe-

cial tool, otherwise crankshaft may be misaligned.

• Apply engine oil to the crankshaft bearings.

• Install the balancer shaft drive gear .

NOTE:

Make sure that the hole in the drive gear is aligned with the

pin on the crankshaft.

BALANCER SHAFT

• Install the balancer shaft

TRANSMISSION

• Install the countershaft and driveshaft assemblies.

3-49 ENGINE

• Install the washer , balancer shaft driven gear

washer and shim onto the balancer shaft.

NOTE:

Make sure that the key is aligned with the keyway.

• Align the punch mark on the balancer shaft driven

gear with the punch mark on the balancer shaft drive

gear

GEARSHIFT CAM AND GEARSHIFT

FORKS

• Align the pin groove of gearshift cam stopper plate

with the pin on the gearshift cam.

• Install the gearshift forks to their respective gears.

• Install the gearshift cam stopper

• Install the gearshift cam into the crankcase.

ENGINE 3-50

• Install the gearshift fork shafts

NOTE:

Position the gearshift cam as shown in Fig. so that the

gearshift fork shafts can be installed easily.

• Install the the gearshift cam stopper spring

CRANKCASE

• Wipe both crankcase mating surfaces with a cleaning

solvent.

• Apply SUZUKI BOND "1215" uniformly to the mating

surface of the right crankcase and assemble the cases

within a few minutes.

99000-31110: SUZUKI BOND "1215"

3-51 ENGINE

• Install the dowel pins into the left half of the crankcase.

• Install the O-ring

A CAUTION

Use a new O-ring

• Apply engine oil to the conrod big end and transmission

gears.

• Tighten the crankcase bolts to the specified torque.

Crankcase bolt: 11 N-m (1.1 kg-m, 8,0 Ib-ft)

NOTE:

Install the clamp to the bolt .

NOTE:

* After the crankcase bolts have been tightened, make

sure that the crankshaft, countershaft and driveshaft ro-

tate smoothly.

* If these shafts do not rotate smoothly, try to free it by

tapping with a plastic hammer.

• Install the the gearshift cam stopper.

GENERATOR ROTOR

• Remove any grease from the tapered portion of the gen-

erator rotor and crankshaft.

• Install the washer so that the convex side of it faces

the crankcase bearing.

• Install the bearing

• Install the starter driven gear

• Install the generator rotor key onto the crankshaft.

• Install the generator rotor securely.

• Apply a small quantity of THREAD LOCK "1303" to the

generator rotor nut.

99000-32030: THREAD LOCK SUPER "1303"

• Tighten the generator rotor nut to the specified torque

using the special tool.

09930-44913: Rotor holder

Generator rotor nut: 160 N ■ m (16.0 kg-m, 115.5 Ib-ft)

DRIVESHAFT RETAINER

• Install the washer and circlip to the driveshaft.

CAUTION Use a new

circlip

PRIMARY DRIVE GEAR

• Install the cam chain sprocket , cam chain sprocket

key and primary drive gear key

3-53 ENGINE

• Install the primary drive gear , wave washer and

primary drive gear nut

NOTE:

This nut has left hand threads.

09930-44913: Rotor holder

Primary drive gear nut :

100 N-m (10.0 kg-m, 72.5 Ib-ft)

BALANCER SHAFT BOLT

• Apply a small quantity of THREAD LOCK "1342" to the

balancer shaft bolt.

99000-32050: THREAD LOCK "1342"

• Tighten the balancer shaft bolt to the specified torque

using the special tool.

09930-44913: Rotor holder Balancer shaft

bolt: 39 N-m (3.9 kg-m, 28.0 Ib-ft)

GEARSHIFT CAM DRIVEN GEAR

• Install each pawl into the gearshift cam driven gear.

Gearshift pawl

Spring Gearshift cam

driven gear

NOTE:

The large shoulder must face to the outside.

• Apply a small quantity of THREAD LOCK "1303" to the

gearshift shaft stopper

99000-32030: THREAD LOCK SUPER "1303"

• Tighten the gearshift shaft stopper to the

specified torque.

Gearshift cam stopper: 19 N-m (1.9 kg-m, 13.5 Ib-ft)

• Tighten the primary drive gear nut to the specified

torque using the special tool.

ENGINE 3-54

• Install the gearshift cam driven gear assembly.

• Install the pawl lifter and cam guide

NOTE:

Apply a small quantity of THREAD LOCK "1342" to the

threads of the screws.

• Install the return spring to the gearshift shaft as shown.

• Install the gearshift shaft.

NOTE:

Align the center teeth on the gearshift shaft with the center

teeth on the gearshift cam driven gear.

OIL PUMP

• Apply engine oil to the sliding surfaces of the oil pump

case, outer rotor, inner rotor and shaft, before mounting the

oil pump.

• Apply a small quantity of THREAD LOCK "1342" to the oil

pump mounting screws and tighten them.

99000-32050: THREAD LOCK "1342"

• Install the washer and pin

• Install the oil pump driven gear and circlip

99000-32050: THREAD LOCK "1342"

3-55 ENGINE

CLUTCH

• Install the washer and spacer onto the counter-

shaft.

NOTE:

Apply engine oil to the inside and outside surfaces of the

spacer.

• Install the primary driven gear assembly and thrust

washer onto the countershaft.

NOTE:

When engaging the primary drive and driven gears, turn

the primary driven gear assembly to the counterclockwise.

Clutch pressure plate

Push piece

Clutch drive plate No.1 (T: 3.00)

Clutch driven plate

Clutch drive plate No.2 (T: 3.50)

Clutch push rod

Concaved washer

Washer seat

Clutch sleeve hub

Clutch housing

Oil pump drive gear

ENGINE 3-56

• Install the clutch sleeve hub and lock washer.

• Install the clutch sleeve hub nut, and tighten it to the

specified torque using the special tool.

09920-53740: Clutch sleeve hub holder

Clutch sleeve hub nut: 50 N-m (5.0 kg-m, 36.0 Ib-ft)

• Bend the lock washer securely.

• Install the washer seat and spring washer as

shown.

• Install the clutch drive plate No.2

• Install the clutch drive plates No.1 and driven plates

one by one into the clutch sleeve hub.

• Install the clutch push rod

• Install the push piece , bearing and washer

• Install the clutch pressure plate , clutch springs and

clutch spring mounting bolts.

• Hold the generator rotor using the special tool and tight-

en the clutch spring mounting bolts to the specified

torque in a crisscross pattern.

09930-44913: Rotor holder

Clutch spring mounting bolt:

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

NOTE:

Make sure that the clutch pressure plate is installed cor-

rectly.

• Loosen the lock nut , and turn in the release screw

to feel resistance.

• From that position, turn out the release screw turn,

and tighten the lock nut by holding the release screw

3-57 ENGINE

CLUTCH COVER

• Install the two dowel pins and new gasket

• Tighten the clutch cover bolts securely.

A CAUTION

Install the new gasket washer to the bolt .

STARTER IDLE GEAR

• Install the starter idle gear

A CAUTION

Apply engine oil to the starter idle gear

GENERATOR COVER

• Install the dowel pins and a new gasket

• Install the generator cover and tighten the bolts securely.

NOTE:

Install the wire harness clamp with the bolt

NEUTRAL SWITCH

• Install the spring and neutral switch contact and

new O-ring

• Install the neutral switch.

ENGINE SPROCKET SPACER

• Apply SUZUKI SUPER GREASE "A" to the O-ring of

the engine sprocket spacer and the oil seal lip.

99000-25010: SUZUKI SUPER GREASE "A"

A CAUTION

Use a new O-ring

* Install the engine sprocket spacer onto the driveshaft.

NOTE:

* The oil hole on the spacer should be on the engine

side.

* Be careful that the oil seal lip does not turn in.

• Install the oil seal retainer .

• Bend the tabs on the oil seal retainer to lock the bolts.

• Pass through the neutral switch lead wire inside of

the guide

• Clamp the neutral switch lead wire and generator lead

wire with the clamp

STARTER MOTOR

• Install the starter motor.

A CAUTION

Use a new O-ring.

NOTE:

Apply grease to the O-ring.

99000-25010: SUZUKI SUPER GREASE "A"

3-59 ENGINE

PISTON AND PISTON RING

• First, install a spacer into the oil ring groove and then

install the two side rails . The spacer and side rails

do not have a specific top or bottom when they are

new. When reassembling used parts, install them in their

original place and direction.

A CAUTION

When installing the spacer, be careful not to allow

its two ends to overlap in the piston ring groove.

INCORRECT

• Same way in which to distinguish the 1st and 2nd piston

rings:

1. Their ring face shapes are different.

2. The 1st piston ring's face is chrome-plated.

3. The 2nd piston ring appears darker in color.

• The 1st and 2nd piston should be installed with their

marks facing up.

• Position the piston ring gaps as shown.

NOTE:

Before inserting the piston into the cylinder, check that the

gaps are properly positioned.

Upper

side

rail

• 1st ring

IN. • Spacer

EX.

• 2nd ring

• Lower side

rail

ENGINE 3-60

The following are reminders for piston installation:

• Before Installing the piston pin, apply molybdenum oil

solution onto its surface.

• Apply engine oil to the big and small ends of the conrod.

• Place a clean rag over the cylinder base to prevent the

piston pin circlip from dropping into crankcase. Install the

piston pin circlip with long-nose pliers.

A CAUTION

Use a new piston pin circlip to prevent circlip failure.

• Install the piston with the arrow mark facing towards

the exhaust side.

CYLINDER

Before installing the cylinder, apply engine oil to the sliding

surface of the piston.

• Install the dowel pins into the crankcase and then Install

the cylinder gasket

A CAUTION

Use a new gasket to prevent oil leakage.

• Make sure that the piston rings are properly positioned,

and insert the piston into the cylinder.

NOTE:

When mounting the cylinder, keep the cam chain taut. The

cam chain must not be caught between the cam chain

drive sprocket and crankcase when crankshaft is rotated.

• Temporarily tighten the cylinder base nuts.

• Install the cam chain guide

3-61 ENGINE

CYLINDER HEAD

• Install the dowel pins into the cylinder and then install the

cylinder head gasket onto the cylinder.

A CAUTION

Use a new gasket to prevent gas leakage.

• Place the cylinder head onto the cylinder.

• Cylinder head nuts and washers must be installed cor-

rectly as shown.

Copper washer

Steel washer

• Tighten the cylinder head nuts (10-mm) to the specified

torque in a crisscross pattern.

Cylinder head nut (10-mm): 38N-m

(3.8 kg-m, 27.5 Ib-ft)

• Tighten the cylinder base nuts (2) and cylinder head nuts

(6-mm) (D to the specified torque.

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

Cylinder head nut (6-mm) ®: 10 N-m

(1.0 kg-m, 7.0 Ib-ft)

ENGINE 3-62

CAMSHAFT

• Turn the crankshaft counterclockwise, and align the T

line on the generator rotor with the mark on the

generator cover while keeping the cam chain tight.

I A CAUTION]

If the crankshaft is turned without drawing the

cam chain upward, the cam chain will catch be-

tween crankcase and cam chain drive sprocket.

NOTE:

Just before installing the camshaft into the cylinder head,

apply molybdenum oil solution to the camshaft journals and

cam faces. Also, apply engine oil to the camshaft journal

holders.

• Install the C-ring into the ring groove of the cylinder

head.

• Install the cam chain.

• Install the camshaft and camshaft sprocket

• Face the notch on the camshaft towards the intake

side.

• Align the engraved line marks on the camshaft so it is

parallel with mating surface of the cylinder head and cyl-

inder head cover.

• Engage the cam chain on the camshaft sprocket with the

locating pin hole at one o'clock position.

NOTE:

Do not rotate the crankshaft while installing the camshaft or

cam chain.

• Install the lock washer so that it is covering the locating

pin.

NOTE:

Apply a small quantity of THREAD LOCK SUPER "1303" to

the threads of the camshaft sprocket bolts.

99000-32030: THREAD LOCK SUPER "1303"

• Tighten the camshaft sprocket bolts to the specified

torque.

Camshaft sprocket bolt: 15 N-m (1.5 kg-m, 11.0 Ib-ft)

3-63 ENGINE

• Bend the lock washer securely.

Camshaft

Bolt

Lock washer

Camshaft sprocket

• Install the camshaft end cap.

CAM CHAIN TENSION ADJUSTER

NOTE:

* Before installing the cam chain tension adjuster, lock the

tension spring with a flat-head screwdriver.

* Before installing the cam chain tension adjuster, turn the

crankshaft counterclockwise to remove any cam chain

slack between the cam chain drive sprocket and cam-

shaft sprocket.

* Install a new gasket and the cam chain tension adjuster

onto the cylinder with the two bolts and tighten them to

the specified torque.

Cam chain tension adjuster bolt:

7 N-m (0.7 kg-m, 5.0 Ib-ft)

• After installing the cam chain tension adjuster, turn the

screwdriver counterclockwise. As the slot in the cam

chain tension adjuster turns, the tension rod advances

under the spring force and pushes the cam chain tension

adjuster against the cam chain.

A CAUTION

After installing the cam chain tension adjuster,

check the cam chain slack to make sure that the

cam chain tension adjuster is working properly.

• Fit the rubber cap.

ENGINE 3-64

CYLINDER HEAD COVER

• Pour motor oil in the oil pocket in the cylinder head.

NOTE:

Turn the crankshaft and check that all the moving parts

(e.g., cam follower, camshaft) work properly.

• Clean the mating surfaces of the cylinder head and head

cover.

• Install the dowel pins.

• Apply SUZUKI BOND N0.1215 uniformly to the mating

surface of the cylinder head cover and install it within a

few minutes.

99000-31110: SUZUKI BOND N0.1215

• Tighten the cylinder head cover bolts to the specified

torque.

Cylinder head cover bolt: 10 N ■ m (1.0 kg-m, 7.0 Ib-ft)

I A CAUTION |

Install the new gasket washer to the bolt

A CAUTION

Be sure to check the valve clearance. (See pp. 2-3

and -4.)

• Install the valve timing inspection caps.

CAUTION

Use new O-rings to prevent oil leakage.

FUEL AND LUBRICATION SYSTEM

----------------------------------------- CONTENTS ------------------------------------------

FUEL TANK AND FUEL VALVE ......................................................... 4- 1

REMOVAL ....................................................................................... 4- 1

INSPECTION ................................................................................... 4- 1

REMOUNTING ............................................................................... 4- 1

CARBURETOR ................................................................................... 4- 2

SPECIFICATIONS ......................................................................... 4-2

I.D. NO. LOCATION ......................................................................... 4-2

CONSTRUCTION ............................................................................ 4-3

REMOVAL ....................................................................................... 4- 4

DISASSEMBLY ............................................................................... 4- 4

CLEANING ...................................................................................... 4- 8

INSPECTION AND ADJUSTMENT .................................................. 4-8

REASSEMBLY ................................................................................ 4- 9

REMOUNTING ............................................................................... 4- 9

LUBRICATION SYSTEM ..................................................................... 4-10

OIL PRESSURE ............................................................................... 4-10

OIL FILTER ...................................................................................... 4-10

OIL SUMP FILTER ........................................................................... 4-10

ENGINE LUBRICATION SYSTEM CHART ....................................... 4-11

4-1 FUEL AND LUBRICATION SYSTEM

FUEL TANK AND FUEL VALVE

REMOVAL

A WARNING

Gasoline is very explosive. Extreme care must be

taken.

• Remove the front seat. (See p. 5-1.)

• Remove the fuel tank mounting bolts.

• Turn the fuel valve to "ON" or "RES" position.

• Disconnect the fuel hose and vacuum hose

• Remove the fuel tank.

• Remove the fuel valve.

INSPECTION

FUEL VALVE

If the fuel filter is dirty with sediment or rust, fuel will not

flow smoothly and loss in engine power may result. Clean

the fuel filter with compressed air. Also check the fuel filter

for cracks.

AWARNING

Gaskets and O-rings must be replaced with new

ones to prevent fuel leakage.

REMOUNTING

• Remount the fuel tank and fuel valve in the reverse order

of removal.

FUEL AND LUBRICATION SYSTEM 4-2

CARBURETOR

SPECIFICATIONS

ITEM

SPECIFICATION

E-01, 02, 04, 25, 34

E-17, 22, 24

Carburetor type

MIKUNI BSR32SS

Bore size

32 mm

I.D. No

13F0

13F2

Idle r/min.

1 300 ± 100 r/min.

Float height

13.0 ±0.5 mm

Main jet (M.J.)

#115

Jet needle (J.N.)

5C60-3rd

Needle jet (N.J.)

P-0

Pilot jet (P.J.)

#17.5

Pilot air jet No. 1 (P.A.J.1)

#87.5

Pilot air jet No.2 (P.A.J.2)

#140

Throttle valve (Th.V.)

#110

Pilot screw (PS.)

turns out

Throttle cable play

2-4 mm (0.08-0.16 in)

Starter plunger cable play

0.5-1.0 mm (0.02-0.04 in)

ITEM

SPECIFICATION

E-03, 28

E-33

Carburetor type

MIKUNI BSR32SS

Bore size

32 mm

I.D. No

13F3

13F4

Idle r/min.

1 300 ± 50 r/min.

Float height

13.0 ±0.5 mm

Main jet (M.J.)

Jet needle (J.N.)

5C65

Needle jet (N.J.)

Pilot jet (P.J.)

Pilot air jet No. 1 (P.A.J.1)

#87.5

Pilot air jet No.2 (P.A.J.2)

#120

Throttle valve (Th.V.)

#110

Pilot screw (PS.)

PRE-SET

Throttle cable play

2-4 mm (0.08-0.16 in)

Starter plunger cable play

0.5-1.0 mm (0.02-0.04 in)

I.D. NO. LOCATION

The carburetor has I.D. Number stamped on its body

according to its specifications.

4-3 FUEL AND LUBRICATION SYSTEM

CONSTRUCTION

Top cap

Spring

Jet needle holder

Washer

Spacer

Jet needle

Piston valve/diaphragm

Diaphragm

Starter plunger

Pilot jet

Jet holder

Main jet

Pilot screw

Starter jet

Throttle stop screw

Float

Gasket

Needle valve seat

Needle valve

Float chamber

FUEL AND LUBRICATION SYSTEM 4-4

REMOVAL

• Remove the fuel tank. (See p. 4-1.)

• Remove the starter plunger

• Loosen the lock nuts and disconnect the throttle

cables

• Remove the overflow hose and air vent hose

• Loosen the clamp screws.

• Remove the carburetor.

DISASSEMBLY

• Remove the fuel hose and vacuum hose

• Remove the throttle stop screw

4-5 FUEL AND LUBRICATION SYSTEM

Remove the diaphragm cover ©.

Remove the diaphragm

• Remove the carburetor top cap.

• Remove the spring and piston valve along with

diaphragm

• Remove the jet needle holder .

FUEL AND LUBRICATION SYSTEM 4-6

• Remove the jet needle

Holder

Spring

Washer

Spacer

The O-ring should be replaced with a new one.

• Remove the float chamber body .

• Remove the screw

• Remove the float pin

• Remove the float assembly along with the needle

valve .

A CAUTION

Do not use a wire to clean the valve seat.

• Remove the screw and needle valve seat

• Remove the main jet and jet holder

• Remove the pilot jet

• Remove the starter jet

• Remove the pilot screw

NOTE:

Before removing the pilot screw , its setting must be de-

termined. Slowly turn the pilot screw clockwise and count

the number of turns until it is lightly seated. When

reassembling the pilot screw, you will want to set it to its

original position.

A CAUTION

Do not use a wire to clean the passage and jets.

A CAUTION

4-7 FUEL AND LUBRICATION SYSTEM

• Remove the pilot air jet No.1 and No.2

• Remove the needle jet

PILOT SCREW REMOVAL (For E-03, -28, -33)

Because harsh cleaning solvents can damage the O-rlng

seals In the pilot system, the pilot system components

should be removed before cleaning.

• Use a 1/8" size drill bit with a drill-stop to remove the

pilot screw plug. Set the drill-stop 6 mm from the end of

the bit to prevent drilling into the pilot screw. Carefully

drill through the plug.

• Thread a self-tapping sheet metal screw into the plug.

Pull on the screw head with pliers to remove the plug.

Carefully clean any metal shavings from the area.

• Slowly turn the pilot screw clockwise and count the num-

ber 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, reinstall the pilot screw to the original set-

ting 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.

Drill-stop

Plug

Pilot screw

Carburetor body

FUEL AND LUBRICATION SYSTEM 4-8

CLEANING

AWARNING

Some carburetor cleaning chemicals, especially

dip-type soaking solutions, are very corrosive and

must be handled carefully. Always follow the

chemical manufacturer's instructions on proper

use, handling and storage.

Clean all jets with a spray-type carburetor cleaner and

dry them using compressed air. Clean all circuits of

the carburetor thoroughly - not just the perceived

problem area. Clean the circuits in the carburetor body

with a spray-type cleaner and allow each circuit to soak,

if necessary, to loosen dirt and varnish. Blow the body

dry using compressed air.

A CAUTION

Do not use a wire to clean the jets or passage-

ways. A wire can damage the jets and passage-

ways. If the components cannot be cleaned with a

spray cleaner it may be necessary to use a dip-

type cleaning solution and allow them to soak. Al-

ways follow the chemical manufacturer's instruc-

tions for proper use and cleaning of the carbure-

tor components.

* After cleaning, reassemble the carburetor with new seals

and gaskets.

INSPECTION AND ADJUSTMENT

Check the following items for any damage or clogging.

* Pilot jet * Needle jet air bleeding hole

* Main jet * Float

* Starter jet * Needle valve

* Diaphragm * Gasket and O-ring

* Pilot screw * Pilot outlet and by-pass holes

NEEDLE VALVE INSPECTION

If foreign matter is caught between the valve seat and the

needle valve, the gasoline will continue flowing and over-

flow. If the valve seat and needle valve are worn beyond

the permissible limits, similar trouble will occur. Converse-

ly, if the needle valve sticks, the gasoline will not flow into

the float chamber. Clean the float chamber and float parts

with gasoline. If the needle valve is worn, as shown in the

illustration, replace it along with a new valve seat. Clean

the fuel passage of the mixing chamber with compressed

air.

CORRECT

INCORRECT

4-9 FUEL AND LUBRICATION SYSTEM

FLOAT HEIGHT ADJUSTMENT

To check the float height, turn the carburetor upside down.

Measure the float height while the float arm is just con-

tacting the needle valve using vernier calipers. Bend the

tongue as necessary to bring the float height to the

specified value.

Float height : 13.0 ±0.5 mm (0.51 ±0.02 in)

09900-20101: Vernier calipers

REASSEMBLY

Reassemble the carburetor in the reverse order of disas-

sembly.

Pay attention to the following points: • Turn the throttle

stop screw until the throttle valve's bottom end is

aligned with the foremost by-pass port

NOTE:

When removing the throttle valve, applying a small quantity

of THREAD LOCK "1342" to the throttle valve mounting

screws and tighten them.

99000-32050: THREAD LOCK "1342"

Face the stamped side of the throttle valve out.

• Install the needle jet as shown.

Large diameter side Bore

side

Small diameter side

Main jet side

REMOUNTING

Remount the carburetor in the reverse order of removal.

* Adjust the following items to the specification.

* Engine idle r/min ........................... See pp. 2-7 and -8.

* Throttle cable play .................................... See p. 2-8.

* Starter plunger cable play ....................... See p. 2-9.

A CAUTION

LUBRICATION SYSTEM

OIL PRESSURE

See p. 2-19.

OIL FILTER

See pp. 2-9 and -10.

OIL SUMP FILTER

When replacing the engine oil, make sure that the oil sump

filter has no tears or damage. Also, be sure to clean the oil

sump filter periodically. (See pp. 3-16, -47 and -51.)

FUEL AND LUBRICATION SYSTEM 4-10

4-11 FUEL AND LUBRICATION SYSTEM

ENGINE LUBRICATION SYSTEM CHART

CHASSIS

----------------------------------------- CONTENTS ------------------------------------------

EXTERIOR PARTS .............................................................................. 5- 1

REMOVAL ........................................................................................ 5- 1

REMOUNTING ............................................................................... 5- 1

FRONT WHEEL ................................................................................. 5-2

CONSTRUCTION ............................................................................. 5-2

REMOVAL ........................................................................................ 5- 3

INSPECTION AND DISASSEMBLY ................................................. 5-3

REASSEMBLY ................................................................................ 5- 5

REMOUNTING ............................................................................... 5- 6

FRONT BRAKE ................................................................................. 5- 7

CONSTRUCTION ............................................................................. 5- 7

BRAKE PAD REPLACEMENT ......................................................... 5-8

BRAKE FLUID REPLACEMENT ...................................................... 5- 8

BRAKE CALIPER REMOVAL AND DISASSEMBLY ......................... 5-9

BRAKE CALIPER INSPECTION ...................................................... 5-10

BRAKE CALIPER REASSEMBLY AND REMOUNTING ................ 5-10

BRAKE DISC INSPECTION .............................................................. 5-11

MASTER CYLINDER REMOVAL AND DISASSEMBLY ..................... 5-11

MASTER CYLINDER INSPECTION ................................................ 5-13

MASTER CYLINDER REASSEMBLY AND REMOUNTING .............. 5-13

FRONT FORK .................................................................................... 5-15

CONSTRUCTION ............................................................................ 5-15

REMOVAL AND DISASSEMBLY .................................................. 5-15

INSPECTION .................................................................................. 5-17

REASSEMBLY AND REMOUNTING ............................................... 5-18

STEERING .......................................................................................... 5-22

CONSTRUCTION ............................................................................ 5-22

REMOVAL AND DISASSEMBLY ................................................... 5-22

INSPECTION ................................................................................... 5-25

REASSEMBLY AND REMOUNTING ............................................... 5-26

REAR WHEEL AND REAR BRAKE ................................................... 5-29

CONSTRUCTION ............................................................................ 5-29

REMOVAL ....................................................................................... 5-30

INSPECTION AND DISASSEMBLY ................................................ 5-31

REASSEMBLY AND REMOUNTING ............................................... 5-33

REAR SUSPENSION .......................................................................... 5-36

CONSTRUCTION ............................................................................ 5-36

REMOVAL ....................................................................................... 5-37

INSPECTION AND DISASSEMBLY ................................................ 5-38

REASSEMBLY AND REMOUNTING ............................................... 5-40

5-1 CHASSIS

EXTERIOR PARTS

REMOVAL

FRONT SEAT

• Remove the seat with the ignition key.

RIGHT FRAME COVER

• Remove the screw.

• Remove the right frame cover.

LEFT FRAME COVER

• Remove the screw.

• Remove the left frame cover.

• Remove the seat lock.

hooked part

REAR SEAT

• Remove the rear seat by removing the bolts.

REMOUNTING

Remount the seats, frame covers, front and rear fenders in

the reverse order of removal.

CHASSIS 5-2

FRONT WHEEL

CONSTRUCTION

ITEM

N-m

kg-m

Ib-ft

6.5

47.0

2.3

16.5

2.3

16.5

Dust cover

Spacer

Bearing

Front wheel

Spacer

Bearing

Brake disc

Speedometer

gearbox

Front axle Axle

pinch bolt Brake

disc bolt

Left

Right

5-3 CHASSIS

REMOVAL

FRONT WHEEL

• Loosen the axle pinch bolt

• Loosen the front axle

• Raise the front wheel off the ground with a jack or wood-

en block.

• Remove the front wheel by removing the front axle

• Remove the dust cover and spacer

• Remove the brake disc.

09900-00410: Hexagon wrench set

INSPECTION AND DISASSEMBLY

SPEEDOMETER GEARBOX

Turn the speedometer gear and check to see that the gear

turns smoothly together with the speedometer pinion.

WHEEL BEARINGS

Inspect the play of the wheel bearings by hand while

they are in the wheel. Rotate the inner race by hand to

inspect it for abnormal noise and smooth rotation. Replace

the wheel bearings if there is anything unusual.

CHASSIS 5-4

Remove the wheel bearings as follows:

• Insert the adapter into the wheel bearing.

• After inserting the wedge bar from the opposite side, lock

the wedge bar into the slit of the adapter.

• Drive out both bearings by striking the wedge bar.

09941-50111: Bearing remover

A CAUTION

The removed bearings should be replaced with new

ones.

FRONT AXLE

Measure the front axle runout using the dial gauge. If the

runout exceeds the limit, replace the front axle.

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

20701: Magnetic stand 09900-21304: V-

block set (100 mm)

Service Limit: 0.25 mm (0.010 in)

WHEEL

Make sure that the wheel runout (axial and radial) does not

exceed the service limit when checked as shown. An ex-

cessive amount of runout is usually due to worn or loose

wheel bearings and can be corrected by replacing the

bearings. If bearing replacement fails to reduce the runout,

replace the wheel.

Service Limit (axial and radial): 2.0 mm (0.08 in)

SPOKE NIPPLE

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

as necessary using a spoke nipple wrench.

09940-60113: Spoke nipple wrench Spoke

nipple: 4.5 N-m (0.45 kg-m, 3.5 Ib-ft)

5-5 CHASSIS

REASSEMBLY

• Apply SUZUKI SUPER GREASE "A" to the bearings be-

fore installing.

99000-25010: SUZUKI SUPER GREASE "A"

• Install the wheel bearings using the special tools as de-

scribed below.

09924-84510: Bearing installer set

09924-84521: Bearing installer set

CAUTION

* First install the left wheel bearing, then install the

right wheel bearing.

* The sealed cover on the bearings must face to the

outside.

Left side Right side Left side Right side

Spacer

BRAKE DISC

• Make sure that the brake disc is clean and free of any

grease. Apply THREAD LOCK SUPER "1360" 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 kg-m, 16.5 Ib-ft)

CHASSIS 5-6

REMOUNTING

Remount the front wheel in the reverse order of removal.

Pay attention to the following points:

• Apply SUZUKI SUPER GREASE "A" to the speedometer

gearbox.

99000-25010: SUZUKI SUPER GREASE "A"

• Align the lugs on the speedometer gearbox with the

recesses on the front wheel.

• Set the speedometer gearbox with cable as shown

in the illustration.

• Tighten the front axle to the specified torque.

Front axle: 65 N-m (6.5 kg-m, 47.0 Ib-ft)

• Tighten the axle pinch bolt @ to the specified torque.

Axle pinch bolt: 23 N-m (2.3 kg-m, 16.5 Ib-ft)

5-7 CHASSIS

FRONT BRAKE

CONSTRUCTION

ITEM

N-m

kg-m

2.3

16.5

1.0

7.0

3.9

28.0

1.8

13.0

7.5

0.75

5.5

¿WARNING

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 stored for long periods of time. When storing the

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 disc with high quality brake cleaner or a neutral detergent.

A CAUTION

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

Reservoir cap

Diaphragm

Brake piston/primary cup

Brake hose

Brake caliper holder

Brake pad

Spring

Dust seal

Piston seal

Piston

Brake hose union bolt

Brake master cylinder mounting bolt

Brake caliper mounting bolt

Brake pad mounting bolt

Brake caliper air bleeder valve

CHASSIS 5-8

BRAKE PAD REPLACEMENT

• Loosen the brake pad mounting bolt

• Remove the brake caliper mounting bolts

• Remove the brake pad mounting bolt

• Remove the brake pads

A CAUTION

* Do not operate the brake lever during or after brake

pad removal.

* Replace the brake pads as a set, otherwise braking

performance will be adversely affected.

• Install the new brake pads and brake pad mounting bolt.

• Tighten the brake caliper mounting bolts and brake

pad mounting bolt to the specified torque.

Brake caliper mounting bolt: 39 N-m

(3.9 kg-m, 28.0 Ib-ft)

Brake pad mounting bolt: 18 N-m

(1.8 kg-m, 13.0 Ib-ft)

NOTE:

After replacing the brake pads, pump with the brake lever a

few times to operate the brake correctly and then check the

brake fluid level.

BRAKE FLUID REPLACEMENT

• Place the motorcycle on a level surface and keep the

handlebars straight.

• Remove the master cylinder reservoir cap and dia-

phragm

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

• Fill the reservoir with new brake fluid.

Specification and Classification: DOT 4

• Connect a cleaner hose to the air bleeder valve

and insert the free end of 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.

A CAUTION

Bleed air from the brake system. (See p. 2-13.)

5-9 CHASSIS

BRAKE CALIPER REMOVAL AND

DISASSEMBLY

• Disconnect the brake hose from the brake caliper by re-

moving the brake hose union bolt and allow the brake

fluid to drain into a suitable receptacle.

• Loosen the brake pad mounting bolt.

• Remove the brake caliper by removing the mounting

bolts .

A CAUTION

Never reuse the brake fluid left over from previous

servicing and which has been stored for long peri-

ods of time.

AWARNING

Brake fluid if it leaks, will interfere with safe running

and discolor painted surfaces. Check the brake

hose and hose joints for cracks and oil leakage.

• Remove the brake pads. (See p. 5-8.)

• Remove the brake caliper holder

• Remove the spring

• Place a rag over the brake caliper piston to prevent it

from popping out and then force out the piston using

compressed air.

A CAUTION

Do not use high pressure air to prevent brake cali-

per piston damage.

• Remove the dust seal and piston seal

A CAUTION

Do not reuse the dust seal and piston seal to pre-

vent brake fluid leakage.

CHASSIS 5-10

BRAKE CALIPER INSPECTION

BRAKE CALIPER

Inspect the brake caliper cylinder wall for nicks, scratches

or other damage.

BRAKE CALIPER PISTONS

Inspect the brake caliper piston for any scratches or other

damage.

BRAKE CALIPER REASSEMBLY AND

REMOUNTING

Reassemble and remount the brake caliper in the reverse

order of removal and disassembly. Pay attention to the fol-

lowing points: • Wash the caliper bore and piston with

the specified

brake fluid. Thoroughly wash the dust seal groove and

piston seal groove.

Specification and Classification: DOT 4

A CAUTION

* Wash the brake caliper components with new

brake fluid before reassembly.

* Do not wipe the brake fluid off after washing the

components.

* When washing the components, use the speci-

fied brake fluid. Never use different types of fluid

or cleaning solvents such as gasoline, ker-osine,

etc.

* Replace the piston seal and dust seal with new

ones.

* Apply brake fluid to all of the seals, brake caliper

bore and piston before reassembly.

• Install the piston seal as shown in the illustration.

• Apply grease to the brake caliper holder.

99000-25100: SUZUKI SILICONE GREASE

Dust seal

Caliper body

Piston seal

5-11 CHASSIS

• Tighten the brake caliper mounting bolts and brake

pad mounting bolt to the specified torque.

• Tighten the brake hose union bolt to the specified

torque.

Brake caliper mounting bolt

39 N-m (3.9 kg-m, 28.0 Ib-ft)

Brake pad mounting bolt : 18 N-m

(1.8 kg-m, 13.0 Ib-ft)

Brake hose union bolt : 23 N-m

(2.3 kg-m, 16.5 Ib-ft)

NOTE:

Before remounting the brake caliper, push the brake caliper

piston all the way into the caliper.

A CAUTION

Bleed air from the system after reassembling the

brake caliper. (See p. 2-13.)

BRAKE DISC INSPECTION

• Remove the front wheel. (See p. 5-3.)

Check the brake disc for damage or cracks. Measure the

thickness using the micrometer.

Replace the brake disc if the thickness is less than the

service limit or if damage is found.

09900-20205: Micrometer (0-25 mm)

Service Limit Brake disc thickness: 4.5 mm

(0.18 in)

Measure the runout using the dial gauge.

Replace the brake disc if the runout exceeds the service

limit.

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

09900-20701: Magnetic stand

Service Limit Brake disc runout: 0.30

mm (0.012 in)

• If either measurement exceeds the service limit, replace

the brake disc. (See pp. 5-3 and -5.)

• Install the front wheel. (See p. 5-6.)

MASTER CYLINDER REMOVAL AND

DISASSEMBLY

• Disconnect the front brake light switch lead wires

• Remove the brake lever

CHASSIS 5-12

• Place a rag underneath the brake hose union bolt on the

master cylinder to catch any spilt brake fluid.

• Remove the brake hose union bolt.

A CAUTION

Immediately wipe off any brake fluid contacting

any part of the motorcycle. The brake fluid reacts

chemically with paint, plastics and rubber materi-

als, etc. and will damage them severely.

• Remove the master cylinder assembly.

• Remove the front brake light switch

• Remove the reservoir cap and diaphragm

• Drain the brake fluid.

• Remove the dust boot

• Remove the circlip using the special tool.

09900-06108: Snap ring pliers

5-13 CHASSIS

• Remove the piston/secondary cup and return spring

MASTER CYLINDER INSPECTION

Inspect the master cylinder bore for any scratches or other

damage.

Inspect the piston surface for any scratches or other dam-

age.

Inspect the primary cup, secondary cup and dust seal for

wear or damage.

MASTER CYLINDER REASSEMBLY AND

REMOUNTING

Reassemble and remount the master cylinder in the re-

verse order of removal and disassembly. Pay attention to

the following points:

A CAUTION

* Wash the master cylinder components with new

brake fluid before reassembly.

* Do not wipe the brake fluid off after washing the

components.

* When washing the components, use the speci-

fied brake fluid. Never use different types of

fluid or cleaning solvents such as gasoline, ker-

osine, etc.

* Apply brake fluid to the master cylinder bore

and all of the master cylinder components be-

fore reassembly.

Specification and Classification: DOT 4

NOTE:

When installing the circlip, make sure that the sharp edge

of the circlip faces outside.

• When reinstalling the brake light switch, align the projec-

tion on the switch with the hole in the master cylinder.

CHASSIS 5-14

• When remounting the master cylinder onto the handle-

bars, align the master cylinder holder's mating surface

with punch mark on the handlebars and tighten the

upper clamp bolt first.

Master cylinder bolt: 10 N-m (1.0 kg-m, 7.0 Ib-ft)

Master cylinder

Clearance

• Install the brake hose union as shown and tighten the

union bolt to the specified torque.

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

A CAUTION

Bleed air from the brake system after reassem-

bling the master cylinder. (See p. 2-13.)

Upper

clamp

bolt

Handlebars

5-15 CHASSIS

FRONT FORK

CONSTRUCTION

ITEM

N-m

kg-m

Ib-ft

2.3

16.5

2.0

14.5

REMOVAL AND DISASSEMBLY

• Remove the front wheel. (See p. 5-3.)

• Remove the brake caliper. (See p. 5-9.)

A CAUTION

Secure the brake caliper to the frame with a string etc.,

taking care not to bend the brake hose.

• Remove the speedometer cable guide from the left fork

leg.

• Remove the front fender and brake hose guide

O-ring

Spacer

Washer

Front fork spring

Damper rod ring

Damper rod

Rebound spring

Inner tube

Dust seal

Oil seal stopper ring

Oil seal

Washer

Slide metal

Guide bushing

Oil lock piece

Outer tube

Gasket

Front fork cap bolt

Damper rod bolt

CHASSIS 5-16

• Remove the front fork after loosening the front fork upper

and lower clamp bolts

NOTE:

Slightly loosen the front fork cap bolt to facilitate later

disassembly.

• Remove the front fork cap bolt , spacer , washer

and spring

• Invert the front fork and stroke it several times to drain

out the fork oil.

• Hold the front fork in the inverted position for a few min-

utes to allow the fork oil to fully drain.

• Remove the dust seal and oil seal stopper ring

• Remove the damper rod bolt

09900-00410: Hexagon wrench set

5-17 CHASSIS

• Remove the damper rod and rebound spring from

the inner tube.

• Separate the inner tube from the outer tube.

• Remove the following parts.

Oil seal Washer

Outer tube slide metal

Inner tube slide metal

The removed oil seal and slide metals should be

replaced with new ones.

• Remove the oil lock piece from the

outer tube.

INSPECTION

DAMPER ROD RING

Inspect the damper rod ring for wear or damage. If it is

worn or damaged, replace it with a new one.

FRONT FORK SPRING

Measure the fork spring free length. If it is shorter than the

service limit, replace it with a new one.

Service Limit: 301 mm (11.9 in)

A CAUTION

CHASSIS 5-18

INNER AND OUTER TUBES

Inspect the inner tube sliding surface and outer tube sliding

surface for scuffing.

REASSEMBLY AND REMOUNTING

Reassemble and remount the front fork in the reverse order

of removal and disassembly. Pay attention to the following

points:

I A CAUTION!

* Wash each metal part with cleaning solvent be-

fore reassembly.

* Never reuse fork oil left over from the last serv-

icing.

* Replace the oil seal and dust seal with new

ones during reassembly.

• Hold the inner tube vertically, clean the metal groove and

install the slide metal by hand.

I A CAUTION!

Do not damage the Teflon coated surface of the

inner tube's slide metal when mounting it.

• Install the outer tube metal , washer and oil seal

to the inner tube.

IA CAUTION]

* When installing the oil seal onto the inner

tube, protect their seal lips to prevent seal lip

damage.

* Before installing the oil seal, apply SUZUKI SU

PER GREASE "A" to its seal lip lightly.

99000-25010: SUZUKI SUPER GREASE "A"

5-19 CHASSIS

• Tighten the damper rod bolt to the specified torque.

09900-00410: Hexagon wrench set

Front fork damper rod bolt: 20 N-m

(2.0 kg-m, 14.5 Ib-ft)

CAUTION

Use a new damper rod gasket to prevent oil

leakage.

• Install the oil seal stopper ring and dust seal

A CAUTION

Make sure that the oil seal stopper ring is fitted

securely.

NOTE:

Before installing the dust seal , apply a small quantity of

SUZUKI SUPER GREASE "A" to the lip of dust seal.

99000-25010: SUZUKI SUPER GREASE "A"

CHASSIS 5-20

• Pour the specified fork oil into the inner tube.

Fork oil type: SUZUKI FORK OIL SS-08 (#10)

99000-99001-SS8: SUZUKI FORK OIL SS-08

Specification

Front fork oil capacity (each leg):

369 ml (12.5/13.0 US/Imp oz)

• Hold the front fork leg in a vertical position and adjust the

fork oil level using the special tool.

09943-74111: Fork oil level gauge

Specification

Front fork oil level: 105 mm (4.1 in)

NOTE:

When adjusting the oil level, remove the fork spring and

compress the inner tube fully.

• Install the fork spring as shown.

NOTE:

The end of the fork spring with the smaller pitch should

be at the bottom of the front fork.

• Install the front fork cap bolt to the inner tube.

A CAUTION

Use a new O-ring to prevent oil leakage.

• Install the front fork to the motorcycle.

• Align the upper surface of the inner tube with the up-

per surface of the steering stem upper bracket

5-21 CHASSIS

• Tighten the front fork lower clamp bolts and front fork

cap bolts to the specified torque.

• Tighten the front fork upper clamp bolts to the speci-

fied torque.

Front fork upper clamp bolt: 23 N-m

(2.3 kg-m, 16.5 Ib-ft)

Front fork lower clamp bolt: 33 N • m

(3.3 kg-m, 24.0 Ib-ft)

Front fork cap bolt: 23 N-m (2.3 kg-m, 16.5 Ib-ft)

• Install the front fender and tighten the mounting bolts

temporarily.

• Install the front brake caliper. (See p. 5-10.)

• Install the front wheel. (See p. 5-8.)

• Move the front fork up and down several times.

• Tighten the front fender mounting bolts securely.

CHASSIS 5-22

STEERING

CONSTRUCTION

ITEM

N-m

kg-m

Ib-ft

6.5

47.0

1.6

11.5

4.5

32.5

2.3

16.5

3.3

24.0

Steering stem upper bracket

Handlebar clamp

Handlebar holder

Steering stem nut

Dust seal

Bearing, upper

Bearing, lower

Steering stem

Steering stem lower cover

Handlebars

Handlebar balancer

Steering stem head bolt

Handlebar clamp bolt

Handlebar holder nut Front

fork upper clamp bolt Front

fork lower clamp bolt

REMOVAL AND DISASSEMBLY

• Remove the front wheel. (See p. 5-4.)

• Remove the front fork. (See p. 5-15.)

• Disconnect the front brake light switch lead wires.

• Remove the front brake master cylinder.

• Remove the right handlebar balancer .

• Remove the handlebar right switch

• Disconnect the throttle cables and remove the throttle

grip .

5-23 CHASSIS

• Remove the left handlebar balancer .

• Remove the handlebar left switch

• Disconnect the clutch lever position switch coupler

• Remove the rear view mirror

• Disconnect the clutch cable.

• Remove the handlebar clamp bolt caps.

• Remove the handlebars by removing the handlebar

clamp bolts.

• Remove the headlight.

• Disconnect the headlight coupler.

• Disconnect the lead wire couplers.

• Remove the headlight housing by removing the

mounting nut.

CHASSIS 5-24

• Remove the steering stem lower cover

• Remove the front brake hose/speedometer cable guide

• Disconnect the speedometer cable

• Remove the speedometer .

• Remove the front turn signal light brackets.

• Remove the handlebar holders

• Remove the steering stem head bolt

^5© - TJ«E

5-25 CHASSIS

• Remove the steering stem nut using the special tool.

09940-14911: Steering stem nut wrench

• Draw out the steering stem lower bracket.

NOTE:

Hold the steering stem lower bracket to prevent it from fal-

ling.

• Remove the dust seal , upper bearing inner race

and upper bearing

• Remove the lower bearing

• Remove the ignition switch using the special tool.

09930-11920: Torx bit JT40H

09930-11940: Bit holder

INSPECTION

Inspect the removed parts for the following abnormalities.

* Handlebar distortion

* Handlebar clamp wear

* Race wear and brinelling

* Bearing wear or damage

* Abnormal bearing noise

* Distortion of the steering stem

• Remove the lower bearing outer race using a chisel.

CHASSIS 5-26

• Drive out the steering stem upper and lower bearing

races using the special tool.

09941-54911: Bearing outer race remover

09941-74910: Steering bearing installer

REASSEMBLY AND REMOUNTING

Reassemble and remount the steering stem in the reverse

order of removal and disassembly. Pay attention to the fol-

lowing points:

• Press in the upper and lower outer races using the spe-

cial tool.

09941-34513: Steering race installer

• Press ¡n the steering stem lower race using the spe-

cial tool.

09941-74910: Steering bearing installer

• Apply grease to the upper and lower bearings.

99000-25010: SUZUKI SUPER GREASE "A"

• Tighten the steering stem nut using the special tool.

09940-14911: Steering stem nut wrench

Steering stem nut: 45 N ■ m (4.5 kg-m, 32.5 Ib-ft)

5-27 CHASSIS

• Turn the steering stem lower bracket about five or six times

to the left and right.

• Loosen the steering stem nut of a turn

NOTE:

This adjustment will vary from motorcycle to motorcycle. Make

sure that the steering turns smoothly and easily in both

directions.

• Install the steering stem upper bracket

• Install the right and left front forks.

• Tighten the front fork lower clamp bolts.

• Tighten the steering stem head bolt to the specified torque.

Steering stem head bolt: 65 N ■ m (6.5 kg-m, 47.0 Ib-ft)

• Align the upper surface of the front fork inner tube with the

upper surface of the steering stem upper bracket.

• Tighten the upper and lower front fork clamp bolts to the

specified torque.

_ Front fork clamp bolt

upper: 23 N-m (2.3 kg-m, 16.5 Ib-ft)

lower: 33 N-m (3.3 kg-m, 24.0 Ib-ft)

• Install the handlebar holders and tighten their nuts

temporarily.

• Install the handlebars with the punch mark aligned with

the handlebar clamp as shown.

• Tighten the handlebar clamp bolts to the specified torque.

Handlebar clamp bolt: 16 N-m (1.6 kg-m, 11.5 Ib-ft)

NOTE:

The gap between the handlebar clamp and holder

should be even.

• Tighten the handlebar holder nuts to the specified torque.

Handlebar holder nut: 45 N-m (4.5 kg-m, 32.5 Ib-ft)

• Install the handlebar clamp bolt caps.

CHASSIS 5-28

NOTE:

When installing the front turn signal lights, insert the projec-

tion on the turn signal light bracket into the hole of steering

stem upper bracket.

• Install the handlebar left switch.

NOTE:

Insert the projection into the hole of the handlebars.

* Install the handlebar right switch.

NOTE:

* Apply SUZUKI SUPER GREASE "A" to the end of the

throttle cable.

99000-25010: SUZUKI SUPER GREASE "A"

* Insert the projection into the hole of the handlebars.

• Install the master cylinder. (See p. 5-13.)

• Install the front brake caliper. (See p. 5-10.)

• Install the front fender and front wheel. (See pp. 5-6 and

-21.)

NOTE:

Hold the front fork legs, move them back and forth and

make sure that the steering is not loose.

A CAUTION

After performing the adjustment and installing the

handlebars, "rock" the front wheel assembly for-

ward and backward to ensure that there is no play

and that the procedure was accomplished correct-

ly. Finally, check to make sure that the steering

stem moves freely from left to right with its own

weight. If play or stiffeness is noticeable, re-adjust

the steering stem nut.

5-29 CHASSIS

REAR WHEEL AND REAR BRAKE

CONSTRUCTION

Spacer

Brake panel

Brake shoe

Spring

Bearing

Spacer

Brake camshaft

Rear wheel

Bearing

Damper

Drive chain guide

Rear sprocket mounting drum

Retainer

Bearing

Dust seal

Spacer

Rear sprocket

Rear axle

Rear axle nut

Rear brake cam lever nut

Rear sprocket mounting nut

ITEM

N-m

kg-m

7.8

56.5

1.0

7.0

5.0

36.0

CHASSIS 5-30

REMOVAL

• Remove the clip and rear brake adjusting nut

• Remove the cotter pin, torque link nut and bolt.

• Remove the rear axle nut

• Raise the rear wheel off the ground with a jack or wood-

en block.

• Loosen the drive chain adjusting nuts , left and right.

• Remove the rear axle.

• Disengage the drive chain from the rear sprocket.

• Remove the rear wheel.

• Remove the rear brake panel

• Remove the rear sprocket with mounting drum from

the rear wheel.

NOTE:

Before separating the rear sprocket and mounting drum,

slightly loosen the rear sprocket bolts.

• Remove the rear sprocket damper

• Remove the drive chain guide and rear sprocket

from the rear sprocket mounting drum.

• Remove the brake shoes from the brake panel.

5-31 CHASSIS

• Remove the brake cam lever bolt and nut.

• Remove the brake cam lever

• Remove the washer , O-ring and brake camshaft

INSPECTION AND DISASSEMBLY

WHEEL BEARING ............................ See pp. 5-3 and -4.

WHEEL AXLE ............................................... See p. 5-4.

WHEEL ......................................................... See p. 5-4.

SPOKE NIPPLE .......................................... See p. 5-4.

REAR SPROCKET MOUNTING

DRUM BEARING ........................................ See p. 5-3.

* Inspect of the rear sprocket mounting drum bearing

in the same manner as the wheel bearing.

Remove the rear sprocket mounting drum bearing as fol-

lows. • Remove the dust seal using the special tool.

09913-50121: Oil seal remover

A CAUTION

The removed dust seal should be replaced with a

new one.

• Remove the rear sprocket mounting drum bearing using

the special tool.

09941-50111: Bearing remover

A CAUTION

The removed bearing should be replaced with a

new one.

CHASSIS 5-32

• Remove the retainer

BRAKE DRUM

Inspect the brake drum and measure the brake drum I.D. to

determine the extent of wear. Replace the brake drum if the

measurement exceeds the service limit. The value of this

limit is indicated inside the brake drum.

09900-20101: Vernier

calipers Service Limit: 130.7 mm

(5.15 in)

BRAKE SHOES

Check the brake shoes and decide whether it should be

replaced or not from the thickness of the brake shoe lining.

Service Limit: 1.5 mm (0.06 in)

A CAUTION

Replace the brake shoes as a set, otherwise braking

performance will be adversely affected.

REAR SPROCKET DAMPER

Inspect the rear sprocket damper for wear and damage.

Replace the rear sprocket damper if there is anything un-

usual.

REAR SPROCKET

Inspect the sprocket's teeth for wear. If they are worn, re-

place the sprocket and drive chain as a set.

Normal wear

Excessive wear

5-33 CHASSIS

REASSEMBLY AND REMOUNTING

Reassemble and remount the rear wheel and rear brake in

the reverse order of removal and disassembly. Pay atten-

tion to the following points:

WHEEL BEARING

• Apply SUZUKI SUPER GREASE "A" to the bearing be

fore installation.

99000-25010: SUZUKI SUPER GREASE "A"

• Press fit the bearing to the wheel using the special tools.

09924-84510: Bearing installer set

09924-84521: Bearing installer set

A CAUTION

* First install the right wheel bearing, then left

wheel bearing.

* The sealed cover on the bearing must face out.

Right side Right side

Right bearing Left bearing

Clearance

Spacer

REAR SPROCKET MOUNTING DRUM BEARING

• Install the rear sprocket mounting drum bearing and dust

seal using the special tool.

09913-76010: Bearing installer

NOTE:

Apply grease to the bearing and dust seal lip before as-

sembling the rear sprocket mounting drum.

99000-25010: SUZUKI SUPER GREASE "A"

Left side

CHASSIS 5-34

REAR SPROCKET

• Tighten the rear sprocket nuts to the specified torque.

Rear sprocket nut: 50 N-m (5.0 kg-m, 36.0 Ib-ft)

NOTE:

The stamped mark on the rear sprocket should face to

the outside.

BRAKE CAMSHAFT

• When installing the brake camshaft, apply SUZUKI SU-

PER GREASE "A" to the camshaft.

99000-25010: SUZUKI SUPER GREASE "A"

BRAKE CAM LEVER

• Install the new O-ring and washer

• Align the notch on the brake camshaft with the slit

in the brake cam lever as shown.

• Tighten the brake cam lever nut to the specified torque.

Brake cam lever nut: 10 N-m (1.0 kg-m, 7.0 Ib-fl)

5-35 CHASSIS

• Apply SUZUKI SUPER GREASE "A" to the brake cam

and pin, and install the brake shoes.

99000-25010: SUZUKI SUPER GREASE "A"

A CAUTION

Be careful not to apply too much grease to the

cam and pin. If grease gets on the lining, brake

slippage will result.

REAR WHEEL

• Tighten the rear torque link nut to the specified torque

and install the new cotter pin.

Rear torque link nut: 13 N-m (1.3 kg-m, 9.5 Ib-ft)

• Adjust the drive chain slack after installing the rear

wheel. (See p. 2-11.)

• Tighten the rear axle nut to the specified torque.

Rear axle nut: 78 N-m (7.8 kg-m, 56.5 Ib-ft)

• Tighten both chain adjusting nuts securely.

• Adjust the rear brake pedal free travel. (See p. 2-14.)

CHASSIS 5-36

REAR SUSPENSION

CONSTRUCTION

ITEM

N-m

kg-m

Ib-ft

2.9

21.0

1.3

9.5

2.9

21.0

7.2

52.0

Right side

Rear shock absorber

Rear torque link

Swingarm

Spacer

Dust seal

Spacer

Drive chain buffer

Swingarm pivot shaft

Rear shock absorber nut

Rear torque link nut Rear

shock absorber bolt

Swingarm pivot nut

Left side

5-37 CHASSIS

REMOVAL

• Remove the rear wheel. (See p. 5-30.)

• Remove the drive chain case.

• Remove the rear brake cable holder

• Remove the rear brake cable from the swingarm.

• Remove the shock absorbers .

• Remove the swingarm pivot shaft end caps.

• Remove the swingarm pivot nut and washer.

• Remove the swingarm by removing the pivot shaft.

CHASSIS 5-38

• Remove the rear torque link from the swingarm.

• Remove the chain buffer from the swingarm.

• Remove the spacers

INSPECTION AND DISASSEMBLY

SWINGARM PIVOT SPACERS AND DUST SEALS

Inspect the swingarm pivot spacers and dust seals for

damage. If any defects are found, replace the spacer with a

new one.

SWINGARM NEEDLE BEARINGS

Insert the spacers into the needle bearings, move the

spacer up and down and check for any play. If there is

excessive play, replace the bearing(-s) with a new one.

5-39 CHASSIS

• Remove the swingarm needle bearings using the special

tools.

09923-74510: Bearing remover

09930-30102: Sliding shaft

A CAUTION

The removed needle bearings should be replaced with new

ones.

SWINGARM

Inspect the swingarm for damage.

If any defects are found, replace the swingarm with a new

one.

CHAIN BUFFER

Inspect the chain buffer for wear and damage. If any defects

are found, replace the chain buffer with a new one.

SWINGARM PIVOT SHAFT

Measure the pivot shaft runout using the dial gauge. If the

pivot shaft exceeds the service limit, replace it with a new

one.

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

20701: Magnetic stand 09900-21304: V-

block (100 mm)

Service Limit: 0.3 mm (0.01 in)

REAR SHOCK ABSORBER

Inspect the rear shock absorber for damage and oil leakage.

If any defects are found, replace the rear shock absorber with

a new one.

A CAUTION

Do not attempt to disassemble the rear shock absorber. It

is unserviceable.

CHASSIS 5-40

REASSEMBLY AND REMOUNTING

Reassemble and remount the swingarm and rear shock

absorber in the reverse order of removal and disassembly.

Pay attention to the following points: • Press the needle

bearings into the swingarm pivot using a suitable

socket and the special tool. (See p. 5-36.)

09924-84521: Bearing installer set

NOTE:

Install the needle bearings with the stamped mark facing

out.

• Apply grease to the spacers, dust seals and needle

bearings.

99000-25010: SUZUKI SUPER GREASE "A"

• Install the rear torque link to the swingarm.

• Tighten the rear torque link nut to the specified torque.

Rear torque link nut: 13 N-m (1.3 kg-m, 9.5 Ib-ft)

• Install the new cotter pin.

• Install the swingarm and tighten the swingarm pivot nut

to the specified torque.

Swingarm pivot nut: 72 N■ m (7.2 kg-m, 52.0 Ib-ft)

5-41 CHASSIS

• Install the rear shock absorber and tighten the mounting

bolts and nuts to the specified torque.

Shock absorber mounting bolt/nut: 29 N-m

(2.9kg-m,21.0lb-ft)

NOTE:

Install the rear shock absorbers with the spring tension ad-

justing holes facing out.

• Install the rear wheel and rear brake. (See p. 5-35.)

• Adjust the rear shock absorber spring pre-load.

Spring pre-load (STD): 3/5 position

After installing the rear suspension and rear wheel, adjust

the following before riding.

* Drive chain slack ...................................... See p. 2-11

* Rear brake pedal free travel .................... See p. 2-14

* Tire pressure ............................................ See p. 2-15

ELECTRICAL SYSTEM

----------------------------------------- CONTENTS ------------------------------------------

CAUTIONS IN SERVICING ................................................................. 6- 1

LOCATION OF ELECTRICAL COMPONENTS ................................. 6-3

CHARGING SYSTEM ....................................................................... 6-5

DESCRIPTION ................................................................................ 6- 5

TROUBLESHOOTING ..................................................................... 6- 6

INSPECTION ................................................................................... 6- 7

STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK

SYSTEM ............................................................................................. 6-10

STARTER SYSTEM DESCRIPTION ................................................ 6-10

SIDE-STAND/IGNITION INTERLOCK SYSTEM DESCRIPTION ... 6-10

TROUBLESHOOTING ....................................................................... 6-11

STARTER MOTOR REMOVAL AND DISASSEMBLY ...................... 6-12

STARTER MOTOR INSPECTION .................................................... 6-12

STARTER MOTOR REASSEMBLY .................................................. 6-13

STARTER RELAY INSPECTION ..................................................... 6-14

SIDE-STAND/IGNITION INTERLOCK SYSTEM PART

INSPECTION ................................................................................... 6-15

IGNITION SYSTEM ........................................................................... 6-18

DESCRIPTION ............................................................................... 6-18

TROUBLESHOOTING ..................................................................... 6-19

INSPECTION ................................................................................... 6-20

SPEEDOMETER ................................................................................. 6-24

REMOVAL AND DISASSEMBLY .................................................... 6-24

INSPECTION ................................................................................... 6-25

LAMPS ................................................................................................ 6-26

HEADLIGHT AND POSITION LIGHT .............................................. 6-26

BRAKE LIGHT/TAILLIGHT ............................................................. 6-27

TURN SIGNAL LIGHTS ................................................................. 6-28

RELAYS .............................................................................................. 6-29

STARTER RELAY ........................................................................... 6-29

TURN SIGNAL/SIDE-STAND RELAY ............................................... 6-29

SWITCHES ....................................................................................... 6-30

BATTERY ........................................................................................... 6-31

SPECIFICATIONS .......................................................................... 6-31

INITIAL CHARGING ........................................................................ 6-31

SERVICING ..................................................................................... 6-32

RECHARGING OPERATION ........................................................... 6-33

6-1 ELECTRICAL SYSTEM

CAUTIONS IN SERVICING

CONNECTORS

• When disconnecting a connector, be sure to hold the ter-

minals; 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 be-

fore disconnecting it. When connecting a connector,

push it in until the lock clicks shut.

• When disconnecting the coupler, be sure to hold the cou-

pler; 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 "WIRE, CABLE AND HOSE ROUTING" (See

pp. 7-11 to -18.) for proper clamping procedures.

• Bend the clamp properly, as shown in the illustration.

• When clamping the wire harness, do not allow it to hang

down.

• Do not use wire or any other substitute for the band-type

clamp.

CORRECT INCORRECT

FUSES

• When a fuse blows, always investigate the cause, cor-

rect the problem and then replace the fuse.

• Do not use a fuse of a different capacity.

• Do not use any substitute for the fuse (e.g., wire).

SEMI-CONDUCTOR EQUIPPED PARTS

• Do not drop any part that contains a semi-conductor

(e.g., ignitor unit, regulator/rectifier).

• When inspecting the part, follow the inspection instruc-

tions carefully. Neglecting proper procedures may cause

this part to be damaged.

ELECTRICAL SYSTEM 6-2

BATTERY

• The MF battery used in this motorcycle does not require

maintenance (e.g., electrolyte level inspection, distilled

water replenishing).

• During normal charging, no hydrogen gas is produced.

However, if the battery is overcharged, hydrogen gas

may be produced. Therefore, be sure that there are no

fire or spark sources nearby (e.g., short-circuit) 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 dif-

ferent 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 disas-

sembly or servicing, be sure to disconnect the battery

() lead wire, first.

• When connecting the battery lead wires, be sure to con-

nect the battery () lead wire, first.

• If the terminal is corroded, remove the battery, pour

warm water over it and clean it using a wire brush.

• After connecting the battery, apply a light coat of grease

to the battery terminals.

• Reinstall the cover over the battery () terminal.

WIRING PROCEDURE

• Properly route the wire harness according to "WIRE,

CABLE AND HOSE ROUTING". (See pp. 7-11 to -18.)

USING THE MULTI CIRCUIT TESTER

• Properly use the multi circuit tester and probes.

Improper use can cause damage to the motorcycle and

tester.

• If the voltage and current values are not known, begin

measuring in the highest range.

• When measuring the resistance, make sure that no volt-

age is applied. If voltage is applied, the tester will be

damaged.

• After using the tester, turn the switch to the OFF position.

CAUTION

Before using the multi circuit tester, read its

instruction manual.

6-3 ELECTRICAL SYSTEM

LOCATION OF ELECTRICAL COMPONENTS

Clutch lever position switch

Ignitor

Turn signal/side-stand relay

Fuse box

Ignition coil

Horn

Generator

Neutral switch

Side-stand switch

Regulator/rectifier

ELECTRICAL SYSTEM 6-4

Front brake light switch

Rear brake light switch

Starter motor

Starter relay

Main fuse

Battery

6-5 ELECTRICAL SYSTEM

CHARGING SYSTEM

DESCRIPTION

The circuit of the charging system is indicated in the figure, which is composed of an AC generator,

regulator/rectifier unit and battery.

The AC current generated from AC generator is converted by rectifier and is turned into DC current,

then it charges the battery.

ELECTRICAL SYSTEM 6-6

TROUBLESHOOTING

Battery runs down quickly.

Check accessories which use excessive

amounts of electricity.

Accessories

are installed • Remove accessories.

No accessories

Check the battery for current

leaks. (See p. 6-7.)

No current leaks

Measure the charging voltage

between the battery terminals.

(See p. 6-7.)

Correct

• Short circuit of the wire harness.

• Loose or disconnected wires.

• Faulty battery.

• Abnormal driving condition.

Incorrect

Measure the continuity of the

stator coil. (See p. 6-8.)

No continuity • Faulty stator coils or

disconnected coupler.

Continuity

Inspect generator no-load

voltage. (See p. 6-8.)

No good

• Faulty generator rotor or

stator coil.

Inspect regulator/rectifier.

(See p. 6-9.) • Faulty regulator/rectifier.

Good

Inspect the wirings.

Good

-No good-

• Short circuit of wire harness.

• Poor contact of couplers.

• Faulty battery.

Others

Current leaks

Good

No good

Battery overcharges

• Faulty regulator/rectifier

• Faulty battery

• Poor contact of stator coil coupler

6-7 ELECTRICAL SYSTEM

INSPECTION

BATTERY LEAK CURRENT INSPECTION

• Remove the front seat and right frame cover. (See p.

5-1.)

• Turn the ignition switch to the OFF position.

• Disconnect the battery lead wire.

• Connect the tester between the battery terminal and

the battery lead wire.

NOTE:

Leakage is evident if the reading is over 1mA.

Battery current leak: Under 1mA

A CAUTION

* 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 the current.

When checking to find the excessive current leak, remove

the couplers and connectors, one by one, checking each

part.

CHARGING OUTPUT INSPECTION

• Remove the front seat and right frame cover. (See p.

5-1.)

• Start the engine, turn the lighting switch to ON and the

dimmer switch to HI, and run the engine at 5 000 r/min.

Measure the DC voltage between the and battery

terminals with a tester. If the tester reads under 13.5V or

over 15.0V, inspect the stator coil and regulator/rectifier.

A CAUTION

If the tester is set for current or resistance readings

and voltage is applied across the test probes,

damage will result. Therefore, it is important that the

tester knob on the tester be set to the proper

position before making any measurements.

NOTE:

When making this test, be sure that the battery is fully-

charged.

Charging output

Standard: 13.5-15.0V at 5 000 r/min.

ELECTRICAL SYSTEM 6-8

STATOR COIL RESISTANCE

• Remove the front seat. (See p. 5-1.)

• Remove the fuel tank. (See p. 4-1.)

• Disconnect the stator coil coupler.

Measure the resistance between the three lead wires using

a tester.

Also check that the stator core is insulated.

If the resistance is incorrect, replace the stator coil with a

new one.

Stator coil resistance:

GENERATOR NO-LOAD PERFORMANCE INSPECTION

• Remove the front seat. (See p. 5-1.)

• Remove the fuel tank. (See p. 4-1.)

• Disconnect the stator coil coupler.

• Start the engine and keep it running at 5 000 r/min.

Measure the voltage between the three lead wires using a

tester.

If the tester reads under the specified value, replace the

stator coil and pick-up coil, or the generator rotor with a

new one.

Generator no-load performance:

More than 60V (AC) at 5 000 r/min

(When engine is cold)

6-9 ELECTRICAL SYSTEM

REGULATOR/RECTIFIER

• Remove the front seat. (See p. 5-1.)

• Remove the fuel tank. (See p. 4-1.)

• Disconnect the regulator/rectifier couplers.

Measure the voltage between the lead wires in the follow-

ing table.

09900-25008: Multi circuit tester set

Tester knob indication: Diode test

Unit: V

Probe of tester to:

Probe of tester to

B/W

0.5-1.0

0.3-0.7

B/W

1.2-1.5

0.3-0.7

1.2-1.5

0.3-0.7

1.2-1.5

0.3-0.7

1.2-1.5

WIRE COLOR

R: Red

Y: Yellow

B/W: Black with White tracer

NOTE:

If the tester lead under 1.4V, replace the battery of multi

circuit tester when do not connecting the tester probes.

ELECTRICAL SYSTEM 6-10

STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM

STARTER SYSTEM DESCRIPTION

The starter system consists of the following components: the starter motor, starter relay, clutch lever

position switch, side-stand relay, side-stand switch, neutral switch, starter button, engine stop switch,

ignition switch and battery. Pressing the starter button (on the right handlebar switch) energizes the starter

relay, causing the contact points to close, thus completing the circuit from the starter motor to the battery.

The starter motor draws about 80 amperes to start the engine.

SIDE-STAND/IGNITION INTERLOCK SYSTEM DESCRIPTION

This side-stand/ignition interlock system prevents the motorcycle from being started with the side-

stand down. The system is operated by an electric circuit provided between the battery and ignition

coil.

Engine stop

switch

Ignition

switch

Clutch lever

position switch

Fuse

Starter

motor

Neutral

switch

Starter

relay

Starter

button

Side-stand

relay

Side-stand

switch

Engine stop

switch

Side-stand relay

Ignition switch

Fuse

To ignitor

and ignition

coil

Neutral

indicator

light

Battery

Side-stand

switch

Neutral

switch

WIRE COLOR

G : Green

R : Red

Bl : Blue

O : Orange

0/B : Orange with Black tracer

O/W: Orange with White tracer

O/Y : Orange with Yellow tracer

Bl/B: Blue with Black tracer

6-11 ELECTRICAL SYSTEM

TROUBLESHOOTING

Starter motor will not run.

The transmission is in neutral. Grasp

the clutch lever. Turn on the ignition

switch with the engine stop switch in

"RUN" position. Listen for a click from

the starter relay when the starter

button is pushed. Clicks

Check if the starter motor runs

when its terminal is connected to

the battery terminal. (Do not use

a thin "wire" because a large

amount of current flows.)

No click

Run Does not run

• Faulty starter motor

• Faulty starter relay

• Loosen or

disconnected starter motor lead

wire

Measure the starter relay voltage at

the starter relay connectors (be-

tween Y/B and B/W ) when the

starter button is pushed.

No voltage

• Faulty ignition switch

• Faulty engine stop switch

• Faulty clutch lever position switch

• Faulty neutral switch

• Faulty side-stand relay

• Faulty starter button

• Poor contact of connector

• Open circuit in wire harness

Check the starter relay.

(See pp. 6-14 and -15.) No good • Faulty starter relay

• Poor contact of the starter relay

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 side-stand up.

Check the side-stand switch.

(See pp. 6-15 and -16.) No good • Faulty side-stand switch

• Open circuit in wire harness

• Poor contact of connector

Others

Engine does not turn though the starter motor runs.

Voltage

• Faulty starter clutch

ELECTRICAL SYSTEM 6-12

STARTER MOTOR REMOVAL AND

DISASSEMBLY

• Disconnect the starter motor lead wire.

• Remove the starter motor.

• Disassemble the starter motor, as shown in the illustration.

STARTER MOTOR INSPECTION

CARBON BRUSH

Inspect the brushes for abnormal wear, crack or smooth-

ness in the brush holder.

If either carbon brush is defective, replace the brush as-

sembly.

Housing end (Outside)

O-ring

Brush spring

Brush holder

Starter motor case

Armature

O-ring

Housing end (Inside)

O-ring

O-ring (2 pcs)

Oil seal

6-13 ELECTRICAL SYSTEM

COMMUTATOR

Inspect the commutator for discoloration, abnormal wear or

undercut

If the commutator is abnormally worn, replace the arma-

ture.

If the commutator surface is discolored, polish it with #400

sandpaper and wipe it using a clean, dry cloth. If there is

no undercut, scrape out the insulator with a saw blade.

ARMATURE COIL INSPECTION

Measure for continuity between each segment. Measure

for continuity between each segment and the armature

shaft.

If there is no continuity between the segments or there is

continuity between the segments and shaft, replace the ar-

mature with a new one.

OIL SEAL INSPECTION

Check the seal lip for damage or leakage.

If any damage is found, replace the housing end (inside).

STARTER MOTOR REASSEMBLY

Reassemble the starter motor in the reverse order of disas-

sembly. Pay attention to the following points:

A CAUTION

Replace the O-rings with new ones to prevent oil

leakage and moisture.

• Apply SUZUKI SUPER GREASE "A" to the lip of the oil

seal.

99000-25010: SUZUKI SUPER GREASE "A"

ELECTRICAL SYSTEM 6-14

• Apply a small quantity of SUZUKI MOLY PASTE to the

armature shaft.

99000-25140: SUZUKI MOLY PASTE

• Apply SUZUKI SUPER GREASE "A" to the O-rings.

99000-25010: SUZUKI SUPER GREASE "A"

• Apply a small quantity of THREAD LOCK "1342" to the

starter motor housing bolts.

STARTER RELAY INSPECTION

• Remove the front seat and right frame cover. (See p.

5-1.)

• Disconnect the battery lead wire

• Remove the starter relay cover

• Disconnect the starter motor lead wires and starter

relay lead wire coupler

• Remove the starter relay.

Apply 12 volts to terminals and , and measure for

continuity between the positive and negative terminals. If

the starter relay clicks and continuity is found, the relay is

ok.

09900-25008: Multi circuit tester set

Tester knob indication: Continuity test (•))) )

A CAUTION

To starter motor To battery

Do not apply battery voltage to the starter relay

for more than five secondes.

This may overheat and damage the relay coil.

99000-32050: THREAD LOCK "1342"

6-15 ELECTRICAL SYSTEM

Measure the starter relay resistance between the terminals

(and ).

Starter relay resistance: 3-6

SIDE-STAND/IGNITION INTERLOCK

SYSTEM PART INSPECTION

If the interlock system does not operate properly, check

each component. If any abnormality is found, replace the

component with a new one.

NEUTRAL SWITCH

The neutral switch coupler is located under the fuel tank.

• Remove the front seat. (See p. 5-1.)

• Remove the fuel tank. (See p. 4-1.)

• Disconnect the neutral switch coupler and measure the

continuity between Blue and Ground with the transmis-

sion in neutral.

Blue

Ground

ON (in neutral)

OFF (not in neutral)

SIDE-STAND SWITCH

The side-stand switch coupler is located under the fuel

tank.

• Remove the front seat. (See p. 5-1.)

• Remove the fuel tank. (See p. 4-1.)

• Disconnect the side-stand switch lead wire coupler and

measure the voltage between Green and Black/White

lead wires.

09900-25008: Multi circuit tester set Tester

knob indication: Diode test ( )

Green

(Probe)

Black/White

( Probe)

ON (UP-

right position)

0.4-0.6 V

OFF

(DOWN position)

1.4-1.5 V

NOTE:

If the tester read under 1.4V, replace the battery of multi

circuit tester when do not connecting the tester probes.

ELECTRICAL SYSTEM 6-16

TURN SIGNAL/SIDE-STAND RELAY

The turn signal relay is corporated with the side-stand relay

and diode to form the one component part which is called

the turn signal/side-stand relay. It is located under the

luggage box.

• Remove the front seat. (See p. 5-1.)

• Remove the luggage box

SIDE-STAND RELAY INSPECTION

First check the insulation between and terminals with

tester. Then apply 12 volts to and terminals, to

and to , and check the continuity between and . If

there is no continuity, replace turn signal/side-stand relay

with a new one.

6-17 ELECTRICAL SYSTEM

DIODE INSPECTION

Using multi circuit tester, measure the voltage between the

terminals in the following table.

Unit: V

Probe of tester to:

Probe c

tester to:

1.4-1.5

0.4-0.6

09900-25008: Multi circuit tester set Tester

knob indication: Diode test

NOTE:

If the tester read under 1.4V, replace the battery of multi

circuit tester when do not connecting the tester probes.

ELECTRICAL SYSTEM 6-18

IGNITION SYSTEM (DIGITAL IGNITOR)

DESCRIPTION

The fully transistorized ignition system consists of the following components: a generator, ignitor, igni-

tion coil and spark plug. The ignition timing is programmed and stored in the ignitor. The pick-up coil

is mounted in the generator. The induced signal in the pick-up coil is sent to the wave-form

arrangement circuit and the CPU receives this signal and calculates the best ignition timing. The CPU

outputs the signal to the transistor of the ignition coil output circuit which is connected to the primary

windings of the ignition coil which is turned "off" and "on" accordingly. Thus, it induces the secondary

current in the ignition coil's secondary winding and produces the spark between the spark plug gap.

Side-stand relay

Engine stop

switch Fuse

Ignitor

Ignitor power

source circuit

Ignition

switch

Transistor

Ignition coil

Main

fuse

CPU

(Central

Processing

Unit)

Wave

foam

arrange-

ment

circuit

Spark plug

Battery

Pick-up

coil

6-19 ELECTRICAL SYSTEM

TROUBLESHOOTING

Check the ignition system couplers for poor

connections.

* Check that the transmission is in neutral and the engine

stop switch is in the "RUN" position. Grasp the clutch

lever. Check that the fuse is not blown and the battery

is fully-charged before diagnosing.

• Poor connection of couplers

Correct

Measure the battery voltage between input

lead wires (O/W and B/W) at the igniter

with the ignition switch in the "ON" position.

Measure the ignition

coil primary peak

voltage. (See p. 6-

20.) NOTE: The ignition coil peak voltage

inspection method is applicable only with

the multi circuit

tester and the peak

volt adaptor.

Inspect the ignition coil.

(See p. 6-21.)

• Faulty

ignition switch

• Faulty turn signal/side-stand

relay

• Faulty engine stop switch

• Broken wire harness or poor

connection of

related circuit

couplers

Inspect the spark plug. (See

p. 2-4 and -5.)

Incorrect

Correct

• Faulty igniter unit

• Faulty spark plug

• Poor

conne

ction

of the spark plug cap.

• Faulty ignition coil

Correct

Measure the pick-up coil peak voltage and

resistance. (See pp. 6-22 and -23.) NOTE:

The pick-up coil peak voltage inspection is

applicable only with the multi circuit tester

and the peak volt adaptor.

Incorrect • Faulty generator

Correct

No spark or poor spark

Looseness

Correct

Incorrect

Correct

Incorrect

• Open circuit in wiring harness

• Poor connection of ignition

couplers

ELECTRICAL SYSTEM 6-20

INSPECTION

IGNITION COIL PRIMARY PEAK VOLTAGE

• Remove the front seat. (See p. 5-1.)

• Remove the fuel tank. (See p. 4-1.)

• Disconnect the spark plug cap.

• Connect 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 is con-

nected properly and the battery Is fully-charged.

Measure ignition coil primary peak voltage in the following

procedure.

• Connect the multi circuit tester with the peak volt adaptor

as follows.

Probe: White lead wire connector

Probe: Ground

NOTE:

Do not disconnect the ignition coil primary wire.

09900-25008: Multi circuit tester set

A CAUTION

When using the multi circuit tester and peak volt

adaptor, refer to the appropriate instruction manual.

• Shift the transmission into neutral, turn the ignition

switch to the "ON" position and grasp the clutch lever.

• Press the starter button and allow the engine to crank for

a few seconds, and then measure the Ignition coll prima-

ry peak voltage.

• Repeat the above procedure a few times and measure

the highest ignition coil primary peak voltage.

Tester knob indication: Voltage ( )

Ignition coil primary peak voltage: More than

200 V

AWARNING

While testing, do not touch the tester probes and

spark plug to prevent receiving an electric shock.

If the voltage is lower than the standard value, inspect the

ignition coil and the pick-up coil. (See pp. 6-21 to -23.)

Peak volt adaptor

Ignition

coil

New

spark

plug

Ignitor

Battery

6-21 ELECTRICAL SYSTEM

IGNITION COIL RESISTANCE

Measure the ignition coil resistance in both the primary and

secondary windings. If the windings are in sound condition,

their resistance should be close to the specified values.

Ignition coil resistance

Primary: 3-5 (terminal-terminal)

Secondary: 17-28 k ( terminal-Spark plug cap)

IGNITOR

• Remove the front seat. (See p. 5-1.)

• Remove the luggage box.

• Remove the ignitor

Measure the voltage between the terminals in the following

table.

09900-25008: Multi circuit tester set Tester knob

indication: Diode test ( )

i Probe of tester to: /

Probe of tester to:

1.2-1.5

1.1-1.5

1.2-1.5

1.1-1.5

0.9-1.4

1.1-1.5

1.2-1.5

0.5-0.8

0.9-1.4

1.1-1.5

1.2-1.5

0.5-0.8

1.1-1.5

0.3-0.6

1.2-1.5

0.8-1.2

1.2-1.5

1.0-1.5

1.1-1.5

0.4-0.6

1.2-1.5

ELECTRICAL SYSTEM 6-22

PICK-UP COIL PEAK VOLTAGE

• Remove the front seat. (See p. 5-1.)

• Remove the luggage box.

NOTE:

Be sure that all of the couplers are connected properly and

the battery is fully-charged.

• Disconnect the ignitor coupler at the ¡gnitor.

• Measure the pick-up coil peak voltage between the

Green and Blue lead wires on the ignitor coupler.

• Connect the multi circuit tester with the peak volt adaptor

as follows.

Probe: Green lead wire

Probe: Blue lead wire

09900-25008: Multi circuit tester set

A CAUTION

When using the multi circuit tester and peak volt

adaptor, refer to the appropriate instruction manual.

• Shift the transmission into neutral, turn the ignition

switch to the "ON" position and grasp the clutch lever.

• Press the starter button and allow the engine to crank for

a few seconds, and then measure the pick-up coil peak

voltage.

• Repeat the above procedure a few times and measure

the highest pick-up coil peak voltage.

Tester knob indication: Voltage ( )

Pick-up coil peak voltage: More than 5.0 V (Green-Blue)

If the peak voltage measured on the ignitor coupler is lower

than the standard value, measure the peak voltage on the

pick-up coil coupler as follows.

Ignitor

coupler

Pick-up

coil

coupler

Generator

Peak

volt

adaptor

6-23 ELECTRICAL SYSTEM

• Remove the front seat. (See p. 5-1.)

• Remove the fuel tank. (See p. 4-1.)

• Disconnect the pick-up coil coupler and connect the mul-

ti circuit tester with the peak volt adaptor.

Probe: Green lead wire

Probe: Blue lead wire

• Measure the pick-up coil peak voltage in the same man

ner as on the ignitor coupler.

Tester knob indication: Voltage

Pick-up coil peak voltage: More than 5.0 V (Green-Blue)

If the peak voltage on the pick-up coil lead wire coupler is

ok but on the ignitor coupler is out of specification, the wire

harness must be replaced. If both peak voltages are out of

specification, the generator must be replaced and re-

checked.

PICK-UP COIL RESISTANCE

• Remove the seat and fuel tank and disconnect the pick-

up coil coupler.

• Measure the resistance between the lead wires and

ground. If the resistance is not within the specified value,

the generator stator must be replaced.

Pick-up coil resistance: 400-650 (Blue-Green)

(Blue-Ground)

Pick-up

coil

coupler

Generator

Peak volt

adaptor

Pick-up

coil

coupler

Generator

ELECTRICAL SYSTEM 6-24

SPEEDOMETER

REMOVAL AND DISASSEMBLY

• Remove the speedometer.

• Disassemble the speedometer as follows.

Speedometer

Speedometer bracket

Speedometer cover

Socket assy.

6-25 ELECTRICAL SYSTEM

INSPECTION

Check the continuity between lead wires.

If there is no continuity, replace the respective parts.

NOTE:

When checking for continuity, it is not necessary to remove

the speedometer.

WIRE COLOR

B : Black B/W : Black with White tracer

Gr : Gray Bl/B : Blue with Black tracer

Lg : Light green O/G : Orange with Green tracer

Y : Yellow

Bl/B: Neutral

B: Turn signal (L)

Y: High beam

Lg: Turn signal

Gr: Illumination

Neutral

B/W: High beam

illumination

ELECTRICAL SYSTEM 6-26

LAMPS

HEADLIGHT AND POSITION LIGHT

Headlight: 12V 60/55W

Position light: 12V 4W ..... Except for E-03, -24, -28 and -33 models

HEADLIGHT BULB REPLACEMENT

• Remove the headlight.

• Disconnect the socket

• Remove the rubber cap

• Remove the bulb by removing the bulb holder spring

• Remove the position light bulb

• Reassemble the bulb in the reverse order of removal.

A CAUTION

If you touch the bulb with your bare hands, clean

the bulb with a cloth moistened with alcohol or

soapy water to prevent premature bulb failure.

6-27 ELECTRICAL SYSTEM

BRAKE LIGHT/TAILLIGHT

Brake light/Taillight: 12V 21/5W

BRAKE LIGHT/TAILLIGHT BULB REPLACEMENT

• Remove the rubber cap behind the rear fender.

• Push in on the bulb socket , turn it counterclockwise,

and pull it out.

• Remove the brake light/taillight bulb

A CAUTION

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.

• Reassemble the bulb in the reverse order of removal.

ELECTRICAL SYSTEM 6-28

TURN SIGNAL LIGHTS

Turn signal light/Running light: 12V 21/5W ..... For E-03, -28 and -33 models

Turn signal light: 12V 21W ..... For the others

TURN SIGNAL LIGHT BULB REPLACEMENT

• Remove the lens by removing the screws.

• Remove the bulb.

CAUTION ________________________________

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.

• Reassemble the bulb in the reverse order of removal.

CAUTION

Do not overtighten the lens fitting screws.

6-29 ELECTRICAL SYSTEM

RELAYS

STARTER RELAY

The starter relay is located behind the right frame cover.

(See pp. 6-14 and -15.)

TURN SIGNAL/SIDE-STAND RELAY

The turn signal relay is corporated with the side-stand relay

and diode to form the one component part which is called

the turn signal/side-stand relay. It is located under the

luggage box.

• Remove the front seat. (See p. 5-1.)

• Remove the luggage box.

INSPECTION

Before removing the turn signal/side-stand relay, check the

operation of the turn signal light.

If the turn signal light does not light, inspect the bulb, turn

signal switch and circuit connection.

If the bulb, turn signal switch and circuit connection

checked are all right, the turn signal relay may be faulty,

replace it with a new one.

NOTE:

Be sure that the battery is full-charged.

ELECTRICAL SYSTEM 6-30

SWITCHES

Measure each switch for continuity using a tester.

switch assemblies with new ones.

IGNITION SWITCH

If any abnormality is found, replace the respective

STARTER BUTTON

For E-24

LIGHTING SWITCH

(Except for E-03, -24, -28, -33)

HORN BUTTON

FRONT BRAKE LIGHT SWITCH

DIMMER SWITCH

PASSING LIGHT SWITCH

(Except for E-03, -28, -33)

TURN SIGNAL SWITCH

ENGINE STOP SWITCH

WIRE COLOR

B : Black O : Orange

Br : Brown R : Red

Gr : Gray Y : Yellow

Lbl : Light blue W : White

Lg : Light green B/W : Black with

White tracer B/Y : Black with

Yellow tracer B/R : Black with Red

tracer O/B : Orange with Black

tracer O/BI : Orange with Blue

tracer O/R : Orange with Red tracer

O/W : Orange with White tracer O/Y

: Orange with Yellow tracer W/B :

White with Black tracer Y/W :

Yellow with White tracer Y/G :

Yellow with Green tracer

REAR BRAKE LIGHT

SWITCH

CLUTCH LEVER

POSITION SWITCH

6-31 ELECTRICAL SYSTEM

BATTERY

SPECIFICATIONS

Type designation

FTX7L-BS

Capacity

12V, 21.6 kC(6Ah)/10HR

Standard electrolyte

S.G.

1.320 at 20°C (68°F)

Stopper

Anode

plates

Filter

INITIAL CHARGING

FILLING ELECTROLYTE

• Remove the aluminum tape which seals the battery

filler holes

* Remove the caps from the electrolyte container.

NOTE:

* Do not remove or pierce the sealed areas of the elec-

trolyte container.

* After completely filling the battery with electrolyte, use

the caps from the electrolyte container to seal the

battery filler holes.

• Insert the nozzles of the electrolyte container into the

battery's electrolyte filler holes. Hold the electrolyte con-

tainer firmly so that it does not fall. Do not allow any of

the electrolyte to spill.

• Make sure that the air bubbles rise to the top of each

electrolyte container and leave the electrolyte container

in this position for more than 20 minutes.

Upper cover

breather

Terminal

Safety valve

Cathode

plates

Separator

(fiberglass

plate)

ELECTRICAL SYSTEM 6-32

NOTE:

If air bubbles do not rise from any one of the filler ports, tap

the bottom of the electrolyte container two or three times.

Never remove the electrolyte container from the battery

while there is still electrolyte in the container.

• After the electrolyte container is completely empty, re-

move it from the battery and wait about 20 minutes.

• Insert the caps firmly into the filler holes, so that the

top of the caps do not protrude above the upper surface

of the battery's top cover.

A CAUTION

* The charging system for a MF battery is differ-

ent from that of a conventional battery. Only

use the specified MF battery.

* Do not remove the caps once they are installed

in the battery

CORRECT INCORRECT

• Measure the battery voltage using a tester. The tester

should indicate more than 12.5-12.6V (DC), as shown.

If the battery voltage is lower than specification, charge

the battery with a battery charger.

NOTE:

Initial charging for a new battery is recommended if two

years have elapsed since the date of manufacture.

SERVICING

Visually inspect the surface of the battery container. If any

signs of cracking or electrolyte leakage from the sides of

the battery have occurred, replace the battery with a new

one. If the battery terminals are found to be coated with

rust or an acidic white powdery substance, clean the bat-

tery terminals with sandpaper.

6-33 ELECTRICAL SYSTEM

RECHARGING OPERATION

• Measure the battery voltage using a tester. If the voltage

reading is less than 12.0V (DC), recharge the battery

with a battery charger.

I A CAUTION! ________________________

When recharging the battery, remove the battery

from the motorcycle.

NOTE:

While recharging, do not remove the caps on the top of the

battery.

Recharging time: 0.7A for 5 to 10 hours or 3A for 1 hour

I A CAUTION]

Be careful not to permit the charging current to

exceed 3A at any time.

• After recharging, wait at least 30 minutes and then mea-

sure the battery voltage using a tester.

• If the battery voltage is less than 12.5V, recharge the

battery again.

• If the battery voltage is still less than 12.5V after recharg-

ing, replace the battery with a new one.

• When a battery is left unused for a long time, its voltage

needs to be regularly measured. When the motorcycle is

not used for more than one month (especially during the

winter season), measure the battery voltage at least

once a month.

SERVICING INFORMATION

---------------------------------------- CONTENTS ------------------------------------------

TROUBLESHOOTING ......................................................................... 7- 1

WIRING DIAGRAM ............................................................................. 7- 8

WIRE, CABLE AND HOSE ROUTING .................................................. 7-11

FRAME REAR COVER SET-UP ........................................................ 7-19

SPECIAL TOOLS ................................................................................ 7-20

TIGHTENING TORQUE ...................................................................... 7-23

SERVICE DATA ................................................................................ 7-26

7-1 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. Broken, cracked or damaged piston

6. Slow cranking starter motor.

7. Mistimed valves.

8. Valve clearance out of adjustment.

Spark plug not sparking

1. Damaged spark plug.

2. Damaged spark plug cap.

3. Fouled spark plug.

4. Wet spark plug.

5. Defective ignition coil.

6. Open or short in high-tension cord.

7. Defective pick-up coil or ignitor unit.

No fuel reaching the carburetor

1. Clogged or defective fuel valve.

2. Defective carburetor needle valve.

3. Clogged fuel hose.

4. Clogged fuel filter.

Rebore or replace.

Replace.

Repair or replace

Tighten.

Replace

See electrical section.

Adjust.

Replace.

Clean or replace.

Clean and dry or replace.

Replace.

Clean or replace. Replace

with carburetor needle valve

seat. Clean or replace.

Clean or replace.

Engine stalls easily.

1. Fouled spark plug.

2. Defective pick-up coil or ignitor unit.

3. Clogged fuel hose.

4. Clogged carburetor jet.

5. Valve clearance out of adjustment.

Clean or replace.

Replace.

Clean.

Adjust.

SERVICING INFORMATION 7-2

Complaint

Symptom and possible causes

Remedy

Engine is noisy.

Excessive valve chatter

Noisy engine.

1. Excessive valve clearance.

Adjust.

2. Weak or broken valve spring.

Replace.

3. Worn cam surface.

Replace.

4. Worn or burnt camshaft journal. Noise

seems to come from the piston

Replace camshaft.

1. Worn piston.

Replace.

2. Worn cylinder.

Rebore or replace.

3. Carbon build-up in combustion chamber.

Clean.

4. Worn piston pin or piston pin bore.

Replace.

5. Worn piston ring or ring groove. Noise

seems to come from the cam chain

Replace.

1. Stretched cam chain.

Replace cam chain and

sprocket.

2. Worn cam chain sprocket.

Replace cam chain and

sprocket.

3. Improperly working cam chain tension adjuster.

Noise seems to come from the clutch

Repair or replace.

1. Worn countershaft spline.

Replace countershaft.

2. Worn clutch hub spline.

Replace clutch hub.

3. Worn clutch plate teeth.

Replace clutch plate.

4. Distorted clutch plate.

Replace.

5. Worn clutch release bearing.

Replace.

6. Weak clutch damper.

Replace primary driven

gear.

7. Weak clutch spring. Noise seems to come

from the crankshaft

Replace.

1. Rattling bearing.

Replace.

2. Worn or burnt crank pin bearing.

Replace.

3. Worn or burnt ball bearing. Noise seems to

come from the transmission

Replace.

1. Worn or rubbing gear.

Replace.

2. Worn countershaft spline.

Replace countershaft.

3. Worn driveshaft spline.

Replace driveshaft.

4. Worn or rubbing primary gear.

Replace.

5. Worn bearing.

Replace.

Clutch slips.

1. Clutch cable out of adjustment.

Adjust.

2. Weak or broken clutch spring.

Replace.

3. Worn or distorted clutch pressure plate.

Replace.

4. Distorted clutch plate.

Replace.

Clutch drags.

1. Clutch out of adjustment.

Adjust.

2. Some clutch springs are weak, while others are

not.

3. Worn or distorted clutch pressure plate.

Replace.

4. Distorted clutch plate.

Replace.

Transmission will

1. Broken gearshift cam.

Replace.

not shift.

2. Distorted gearshift fork.

Replace.

3. Worn gearshift pawl.

Replace.

7-3 SERVICING INFORMATION

Complaint

Symptom and possible causes

Remedy

Transmission will

not shift back.

1. Broken gearshift shaft return spring.

2. Rubbing or stuck gearshift shaft.

3. Worn or distorted gearshift fork.

Replace.

Repair or replace.

Replace.

Transmission jumps

out of gear.

1. Worn gear.

2. Worn or distorted gearshift fork.

3. Weakened gearshift cam stopper spring.

4. Worn gearshift pawl.

Replace.

Engine idles poorly.

1. Valve clearance out of adjustment.

2. Improper valve seating.

3. Worn valve guide.

4. Worn cam surface.

5. Excessive spark plug gap.

6. Defective ignition coil.

7. Defective pick-up coil or ignitor unit.

8. Spark plug too cold.

9. Incorrect float chamber fuel level.

10. Clogged carburetor jet.

11. Defective generator.

Adjust.

Repair or replace.

Replace.

Adjust or replace.

Replace.

Replace by hot type

plug.

Adjust float height.

Clean.

Replace.

Engine runs poorly in

high-speed range.

1. Weak valve spring.

2. Worn camshaft.

3. Insufficient spark plug gap.

4. Mistimed valves.

5. Ignition not advanced sufficiently due to poorly

working timing advance circuit.

6. Defective ignition coll.

7. Defective pick-up coil or ignitor unit.

8. Low float chamber fuel level.

9. Clogged air cleaner element.

10. Clogged fuel hose, resulting in inadequate fuel

supply to carburetor.

Replace.

Regap or replace.

Adjust.

Replace ignitor unit.

Replace. Replace.

Adjust float height.

Clean or replace.

Clean and prime.

Exhaust smoke is

dirty or thick.

1. Excessive amount of engine oil.

2. Worn cylinder.

3. Worn piston ring.

4. Worn valve guide.

5. Scored or scuffed cylinder wall.

6. Worn valve stem.

7. Defective valve stem oil seal.

8. Worn oil ring side rail.

Check level and drain.

Rebore or replace.

Replace.

Rebore or replace.

Replace valve.

Replace.

Replace oil ring.

Engine lacks power.

1. Insufficient valve clearance.

2. Weak valve spring.

3. Mistimed valves.

4. Worn cylinder.

5. Worn piston ring.

6. Improper valve seating.

7. Fouled spark plug.

8. Incorrect spark plug.

9. Clogged carburetor jet.

10. Incorrect float chamber fuel level.

11. Clogged air cleaner element.

12. Worn camshaft.

13. Air leaked from intake pipe.

14. Excessive amount of engine oil.

Adjust.

Replace.

Adjust.

Rebore or replace.

Replace.

Repair or replace.

Clean or replace.

Replace.

Clean.

Adjust float height.

Clean or replace.

Replace.

Tighten or replace.

Check level and drain.

SERVICING INFORMATION 7-4

Complaint

Symptom and possible causes

Remedy

Engine overheats.

1. Heavy carbon deposit on piston crown.

Clean.

2. Not enough oil in the engine.

Add oil.

3. Defective oil pump or clogged oil circuit.

Replace or clean.

4. Too low in float chambers fuel level.

Adjust.

5. Sucking air from intake pipe.

Retighten or replace.

6. Use incorrect engine oil.

Change.

7. Clogged air Intake with dust.

Clean.

CARBURETOR

Complaint

Symptom and possible causes

Remedy

Starting difficulty.

1. Clogged fuel pipe.

2. Air leaking from joint between starter body and car

buretor.

3. Air leaking from carburetor joint.

4. Improperly working starter plunger.

Clean.

Tighten, adjust or replace

gasket. Tighten or replace

defective parts. Adjust.

Idling or low-speed

trouble.

1. Clogged or loose pilot jet.

2. Air leaking from carburetor joint.

3. Clogged pilot outlet port.

4. Clogged bypass port.

5. Starter plunger not fully closed.

Clean or tighten. Tighten or

replace defective part.

Clean. Clean. Adjust.

Medium-or high

speed trouble.

1. Clogged main jet.

2. Clogged needle jet.

3. Improperly working throttle valve.

4. Clogged fuel filter.

Clean. Clean.

Adjust. Clean or

replace.

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.

CHASSIS

Complaint

Symptom and possible causes

Remedy

Steering is heavy.

1. Overtightened steering stem nut.

2. Broken bearing/race in steering stem.

3. Distorted steering stem.

4. Low tire pressure.

Adjust.

Replace.

Regulate.

Handlebars

wobbles.

1. Loss of balance between right and left front fork

legs.

2. Distorted front fork.

3. Distorted front axle.

4. Twisted tire.

Adjust or replace.

Repair or replace.

Replace.

7-5 SERVICING INFORMATION

Complaint

Symptom and possible causes

Remedy

Front wheel

wobbles.

1. Distorted wheel rim.

2. Worn front wheel bearing.

3. Defective or incorrect tire.

4. Loose front axle.

5. Incorrect front fork oil level.

6. Loose wheel spoke.

Replace.

Tighten.

Adjust.

Tighten.

Front suspension

too soft.

1. Weak spring.

2. Insufficient fork oil.

Replace.

Check level and add.

Front suspension

too stiff.

1. Excessively viscous fork oil.

2. Excessive fork oil.

Replace.

Check level and drain.

Front suspension

too noisy.

1. Insufficient fork oil.

2. Loose front suspension fastener.

Check level and add.

Tighten.

Rear wheel wobbles.

1. Distorted wheel rim.

2. Worn rear wheel bearing.

3. Defective or incorrect tire.

4. Worn swingarm bearing.

5. Loose rear axle nut or swingarm pivot nut.

6. Loosen wheel spokes.

7. Loosen rear suspension fastener.

Replace.

Tighten.

Rear suspension

too soft.

1. Weak rear shock absorber spring.

2. Rear shock absorber leaks oil.

3. Improper suspension setting.

Replace.

Adjust.

Rear suspension

too stiff.

1. Improperly adjusted rear suspension.

2. Bent swingarm.

3. Worn swingarm and rear suspension related

bearings.

Adjust.

Replace.

Rear suspension too

noisy.

1. Loose rear suspension fastener.

2. Worn swingarm bearing.

Tighten.

Replace.

BRAKES

Complaint

Symptom and possible causes

Remedy

Brake power

1. Leakage of brake fluid.

Repair or replace.

insufficient.

2. Worn brake pad.

Replace.

3. Oil in brake pad surface.

Clean brake disc and

brake pads.

4. Worn brake disc.

Replace.

5. Air in hydraulic system.

Bleed.

6. Worn brake shoe.

Replace.

7. Oil in brake shoe surfaces.

Clean.

8. Excessively worn brake drum.

Replace.

9. Excessive brake pedal play.

Adjust.

SERVICING INFORMATION 7-6

Complaint

Symptom and possible causes

Remedy

Brake squeaks.

1. Carbon adhesion on brake pad surface.

2. Tilted brake pad.

3. Damaged wheel bearing.

4. Worn brake pad.

5. Foreign material in brake fluid.

6. Clogged return port of master cylinder.

7. Brake shoe surface glazed.

8. Worn brake shoe.

9. Loose front axle or rear axle nut.

Clean surface with sand-

paper.

Readjust brake pad position

or replace. Replace.

Replace.

Change brake fluid.

Disassemble and clean

master cylinder. Clean

surface with sandpaper.

Replace. Tighten.

Brake lever or pedal

stroke excessive.

1. Air in hydraulic system.

2. Insufficient brake fluid.

3. Incorrect brake fluid.

4. Worn brake camshaft.

5. Excessively worn brake shoes and/or brake drum.

Bleed.

Check level and add.

Bleed any air.

Change.

Replace.

Brake fluid leaks.

1. Loose connection joint.

2. Cracked brake hose.

3. Worn piston seal.

Tighten.

Replace.

Replace

ELECTRICAL

Complaint

Symptom and possible causes

Remedy

No sparking or poor

sparking.

1. Defective ignition coil.

2. Defective spark plug.

3. Defective pick-up coil.

1. Defective ignitor unit.

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. Clogged air cleaner element.

5. Incorrect spark plug (cold type).

Adjust carburetor

Change.

Clean or replace.

Change to hot type 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.

Rebore or replace.

Replace.

Spark plug electrodes

overheat or burn.

1. Incorrect spark plug (hot type).

2. Overheated engine.

3. Loose spark plug.

4. Excessively lean air/fuel mixture.

Change to cold type

spark plug.

Tune-up.

Tighten.

Adjust carburetor.

Generator does not

charge.

1. Open or short in lead wires, or loose lead connec

tions.

2. Shorted, grounded or open stator coil.

3. Shorted or panctured regulator/rectifier.

Repair, replace or

connect properly.

Replace. Replace.

7-7 SERVICING INFORMATION

Complaint

Symptom and possible causes

Remedy

Generator charges

but charging rate is

below the

specification.

1. Lead wires tend to get shorted or open-circuited or

loosely connected at terminal.

2. Grounded or open-circuited stator coils or genera

tor.

3. Defective regulator/rectifier.

4. Defective battery cell plates.

Repair or tighten.

Replace.

Replace. Replace

battery.

Generator

overcharges.

1. Internal short-circuit in the battery.

2. Damaged or defective regulator/rectifier.

3. Poorly grounded regulator/rectifier.

Replace battery.

Replace.

Clean, repair or 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.

Recharge or replace.

Replace.

Repair or replace.

Replace.

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 battery.

Replace.

Battery runs down

quickly.

1. Incorrect charging method.

2. Battery cell plates have lost much of their active ma

terial as a result of overcharging.

3. Internally shorted battery.

4. Excessively low battery voltage.

5. Battery is too old.

Check generator or regu-

lator/rectifier circuit con-

nections, and make nec-

essary adjustment to obtain

specified charging

operation.

Replace battery and correct

charging system. Replace.

Recharge 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 battery.

Replace battery if badly

sulfated.

WIRING DIAGRAM

FOR E-03, -28 and -33

SERVICING INFORMATION 7-8

7-9 SERVICING INFORMATION

FOR E-24

FOR THE OTHERS

SERVICING INFORMATION 7-10

Clamp

Wiring harness

Clamp

Pass through the wiring harness

right side of the clutch cable,

speedometer cable and brake

hose.

Clamp

Brake light/Taillight

Rear turn signal light (L)

Wiring harness

Starter motor

Clamp

Starter motor

lead wire

Clamp

Rear fender

Turn signal/side-stand relay

Air cleaner

Generator

Ignitor

Neutral switch

Side-stand switch

Clamp

Handlebar

switch (L&R)

Handlebar switch (L&R)

Starter motor

Clamp

Side-stand

switch

Clamp

Regulator/rectifier

Neutral switch

Side-stand switch

Clamp

Wiring

harness

Clamp

Starter motor

Wiring harness

High tension cord

(Ignition coil)

Handlebar switch

(L&R) ________

Clamp

Pass through the handlebar

switch (R) lead wire under the

brake hose.

Clamp

Battery

terminal

Rear turn signal

light (R)

Rear turn signal

light (L)

Battery

Brake

light/Taillight

Starter relay

Engine ground

Starter motor

Clamp

Rear brake

switch

Wiring harness

Handlebar switch (L&R)

Starter motor

Generator

Wiring harness

Clamp

Starter motor

Clamp

7-13 SERVICING INFORMATION

Generator lead wire

Neutral switch

Pick-up coil

Clamp

Engine

ground wire

Side-stand switch

lead wire

Clamp

Generator rolor

Neutral switch

lead wire

Side-stand

switch lead wire

Neutral switch

lead wire

Stator coil

SERVICING INFORMATION 7-14

CABLE ROUTING

Clamp

Throttle

cables

Throttle cable (pulling

cable) Throttle cable (returning cable)

Throttle cables

Brake hose

Clamp

Wiring harness

Starter cable

Clamp \ Throttle cable (returning

cable)

Throttle cable (pulling cable)

Clamp

Throttle cables

Starter cable

Pass the throttle cables

outside of the brake hose.

Starter cable

Clamp

Wiring harness

Clamp

Brake hose

Handlebar switch (R)

Clutch cable

Starter cable

Handlebar switch (L)

Starter cable

Clamp

Clutch cable

7-15 SERVICING INFORMATION

Caliper

rubber

bushing Guide

Speedometer cable

Guide

Pass the speedometer cable

outside of the brake hose.

Brake hose

Clamp

100 mm (4.0 in)

Max. 10 mm (0.4 in) 4 Do not

contact the guide to the caliper

rubber bushing.

SERVICING INFORMATION 7-16

Clamp

Seat lock cable

Rear brake

switch cable

Clamp

Rear brake

cable

Rear brake

cable clip

Clamp

Rear brake cable

Clamp

Rear brake

switch cable

7-17 SERVICING INFORMATION

FRONT BRAKE HOSE ROUTING

Clamp

Master

cylinder

Master

cylinder

Clamp

/ Clamp the brake \

\ hose securely. /

Brake hose

Clamp

Speedometer cable

Clamp

/ Clamp the brake \

\ hose securely. /

Brake

caliper

After touching the brake hose

union to the stopper, tighten the

union bolt to the specified torque.

Stopper

SERVICING INFORMATION 7-18

CARBURETOR HOSE ROUTING

Left

Right Left Right

(Engine side) (Air cleaner side)

Carburetor clamp position

VIEW A

Air cleaner

Carburetor

Carburetor air

vent hose

Battery

case

Clamp

Air cleaner drain hose

Carburetor overflow hose

7-19 SERVICING INFORMATION

FRAME REAR COVER SET-UP

Rear fender brace

Rear fender

Frame rear cover

Cushion

Nut

Frame

Spacer

SERVICING INFORMATION 7-20

SPECIAL TOOLS

09900-00401

"L" type hexagon

wrench set

09900-00410 Hexagon

wrench set

09900-06107

Snap ring pliers

09900-06108

Snap ring pliers

09900-09004

Impact driver set

09900-20101

Vernier calipers

(150 mm)

09900-20202

Micrometer

(25-50 mm)

09900-20203

Micrometer

(50-75 mm)

09900-20205

Micrometer

(0-25 mm)

09900-20508

Cylinder gauge set

09900-20605

Dial calipers

09900-20606

Dial gauge

(1/100 mm, 10 mm)

09900-20701

Magnetic stand

09900-20803

Thickness gauge

09900-20805 Tire

depth gauge

09900-21304

V-block set

(100 mm)

09900-22301

09900-22302

Plastigauge

09900-22401

09900-22403 Small

bore gauge

09900-25008 Multi

circuit tester set 09900-26006

Tachometer

09910-20116

Conrod holder

09910-32812

Crankshaft installer

09910-32840

Attachment

09910-34510

Piston pin puller

09913-50121 Oil

seal remover

09913-75510

Bearing installer

09913-75520

Bearing installer

09913-75830

Bearing installer

09913-76010

Bearing installer

09913-84510

Bearing installer

7-21 SERVICING INFORMATION

09913-85210

Bearing installer

09915-64510

Compression gauge

09915-74510

Oil pressure gauge

09916-14510

Valve lifter

09916-14910 Valve

lifter attachment

09916-21111

Valve seat cutter set See p. 3-28.

09916-24450

Solid pilot (N-

100-5.52)

09916-34542 Valve

guide reamer handle

09916-34550 Valve

guide reamer (5.5

mm)

09916-34561

Valve guide reamer

(11.3 mm)

09916-44910

Valve guide remover/

installer

09916-84511

Tweezers

09917-14920

Valve adjuster

wrench

09918-03810

Adaptor

09920-13120

Crankcase separator

09920-53740 Clutch

sleeve hub holder 09923-74510

Bearing remover

09924-84510 Bearing

installer set

09924-84521 Bearing

installer set

09930-10121 Spark

plug socket wrench set 09930-11920

Torx bit JT40H

09930-11940

Bit holder

09930-30102

Sliding shaft

09930-34960

Rotor remover

09930-44913

Rotor holder

09940-14911

Steering stem nut

wrench

09940-52880 Front

fork oil seal installer

set

09940-60113

Spoke nipple wrench

09941-34513 Steering

outer race installer

SERVICING INFORMATION 7-22

09941-50111

Bearing remover

09941-54911

Bearing outer race

remover

09941-74910

Steering bearing

installer

09943-74111 Front

fork oil level gauge

NOTE:

When ordering a special tool, please confirm whether it is available or not.

SERVICING INFORMATION 7-24

CHASSIS

ITEM

N-m

kg-m

Ib-ft

Handlebar clamp bolt

1.6

11.5

Handlebar holder nut

4.5

32.5

Steering stem head bolt

6.5

47.0

Front fork upper clamp bolt

2.3

16.5

Front fork lower clamp bolt

3.3

24.0

Front fork cap bolt

2.3

16.5

Front fork damper rod bolt

2.0

14.5

Front axle

6.5

47.0

Front axle pinch bolt

2.3

16.5

Front brake caliper mounting bolt

3.9

28.0

Front brake pad mounting bolt

1.8

13.0

Front brake hose union bolt

2.3

16.5

Front brake caliper air bleeder valve

7.5

0.75

5.5

Front brake master cylinder mounting bolt

1.0

7.0

Front brake disc bolt

2.3

16.5

Front footrest bolt

2.6

19.0

Swingarm pivot nut

7.2

52.0

Rear axle nut

E-03, -28, -33

6.5

47.0

The others

7.8

56.5

Rear torque link nut (front and rear)

1.3

9.5

Rear shock absorber mounting bolt or nut

2.9

21.0

Rear sprocket nut

5.0

36.0

Rear brake cam lever nut

1.0

7.0

Spoke nipple

4.5

0.45

3.5

7-25 SERVICING INFORMATION

TIGHTENING TORQUE CHART

For other bolts and nuts listed previously, refer to this chart:

Bolt Diameter

(mm)

Conventional or "4" marked bolt

"7" marked bolt

N-m

kg-m

Ib-ft

N-m

kg-m

Ib-ft

1.5

0.15

1.0

0.2

1.5

0.3

2.0

0.5

3.5

0.6

4.5

1.0

7.0

1.3

9.5

2.3

16.5

2.9

21.0

5.0

36.0

4.5

32.5

8.5

61.5

6.5

47.0

135

13.5

97.5

105

10.5

76.0

210

21.0

152.0

160

16.0

115.5

240

24.0

173.5

Conventional bolt "4" marked bolt "7" marked bolt

SERVICING INFORMATION 7-26

SERVICE DATA

VALVE + GUIDE Unit: mm (in)

ITEM

STANDARD

LIMIT

Valve diam.

IN.

(1.0)

EX.

(0.9)

Valve 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.

0.025-0.052

(0.0010-0.0020)

EX.

0.040-0.067

(0.0016-0.0026)

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.

5.460-5.475

(0.2150-0.2156)

EX.

5.445-5.460

(0.2144-0.2150)

Valve stem runout

IN. & EX.

0.05

(0.002)

Valve head thickness

IN. & EX.

0.5

(0.02)

Valve stem end length

IN. & EX.

3.6

(0.14)

Valve seat width

IN. & EX.

0.9-1.1

(0.035-0.043)

Valve head radial runout

IN. & EX.

0.03

(0.001)

Valve spring free length

IN. & EX.

40.1

(1.58)

Valve spring tension

IN. & EX.

18.4-21.6 kg

(40.56-47.62 lbs)

at length 35.0 mm (1.38 in)

7-27 SERVICING INFORMATION

CAMSHAFT + CYLINDER HEAD

Unit: mm (in)

ITEM

STANDARD

LIMIT

Cam height

IN.

34.990-35.040

(1.3776-1.3795)

34.690

(1.3657)

EX.

35.030-35.080

(1.3791-1.3811)

34.730

(1.3673)

Camshaft journal oil clearance

0.032-0.066

(0.0013-0.0026)

0.150

(0.0059)

Camshaft journal holder I.D.

R. side

25.012-25.025

(0.9847-0.9852)

L. side

20.012-20.025

(0.7879-0.7884)

Camshaft journal O.D.

R. side

24.959-24.980

(0.9826-0.9835)

L. side

19.959-19.980

(0.7858-0.7866)

Camshaft runout

IN. & EX.

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.

11.966-11.984

(0.4711-0.4718)

Cylinder head distortion

0.05

(0.002)

Cylinder head cover distortion

0.05

(0.002)

CYLINDER + PISTON + PISTON RING

Unit: mm (in)

ITEM

STANDARD

LIMIT

Compression pressure

1 000-1 400 kPa

/10.0-14.0 kg/cm2\ [

142-199 psi )

800 kPa / 8

kg/cm2 \ {

114 psi j

Piston to cylinder clearance

0.045-0.055

(0.0018-0.0022)

0.120

(0.0047)

Cylinder bore

72.000-72.015

(2.8346-2.8352)

72.085

(2.8380)

Piston diam.

71.950-71.965

(2.8327-2.8333)

Measure at 15 mm (0.6 in) from the skirt end.

71.880

(2.8299)

Cylinder distortion

0.05

(0.002)

Piston ring free end gap

1st

Approx.

7.6

(0.30)

2nd

Approx.

8.8

(0.35)

Piston ring end gap

1st

0.10-0.30

(0.004-0.012)

0.50

(0.020)

2nd

0.10-0.30

(0.004-0.012)

0.50

(0.020)

Piston ring to groove clearance

1st

0.180

(0.0071)

9nH

0.150

(0.0059)

c.\\\

SERVICING INFORMATION 7-28

ITEM

STANDARD

LIMIT

Piston ring groove width

1st

1.01-1.03

(0.040-0.041)

2nd

1.21-1.23

(0.047-0.048)

Oil

2.51-2.53

(0.099-0.100)

Piston ring thickness

1st

0.975-0.990

(0.0384-0.0390)

2nd

1.170-1.190

(0.0461 -0.0469)

Piston pin bore

18.002-18.008

(0.7087-0.7090)

18.030

(0.7098)

Piston pin O.D.

17.992-18.000

(0.7083-0.7087)

17.980

(0.7079)

CONROD + CRANKSHAFT Unit: mm (in)

ITEM

STANDARD

LIMIT

Conrod small end I.D.

18.006-18.014

(0.7089-0.7092)

18.040

(0.7102)

Conrod deflection

3.0

(0.12)

Conrod big end side clearance

0.10-0.65

(0.004-0.026)

1.0

(0.04)

Conrod big end width

20.95-21.00

(0.825-0.827)

Crankshaft web to web width

60.0 + 0.1

(2.362 ± 0.004)

Crankshaft runout

0.05

(0.002)

Balancer spring free length

10.0

(0.39)

OIL PUMP

ITEM

STANDARD

LIMIT

Oil pump reduction ratio

2.812(68/21 x 33/38)

Oil pressure (at 60°C, 140°F)

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

Below 70 kPa (0.7 kg/cm2, 10.0 psi)

at 3 000 r/min.

CLUTCH Unit: mm (in)

ITEM

STANDARD

LIMIT

Clutch cable play

10-15

(0.4-0.6)

Clutch release screw

turn back

Drive plate thickness

No.1

2.92-3.08

(0.115-0.121)

2.62

(0.103)

No.2

3.45-3.55

(0.136-0.140)

3.15

(0.124)

Drive plate claw width

15.9-16.0

(0.626-0.630)

15.0

(0.590)

Driven plate distortion

0.10

(0.004)

Clutch spring free length

40.9

(1.61)

7-29 SERVICING INFORMATION

TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio

ITEM

STANDARD

LIMIT

Primary reduction ratio

3.238(68/21)

Final reduction ratio

2.733(41/15)

Gear ratios

Low

2.636(29/11)

2nd

1.687(27/16)

3rd

1.263(24/19)

4th

1.000(20/20)

Top

0.818(18/22)

Shift fork to groove clearance

0.20-0.40

(0.008-0.016)

0.60

(0.024)

Shift fork groove width

4.25-4.35

(0.167-0.171)

Shift fork thickness

3.95-4.05

(0.156-0.159)

Drive chain

Type

DID520VC5

Links

110

20-pitch length

319.4

(12.57)

Drive chain slack

5-15

(0.2-0.6)

CARBURETOR

ITEM

SPECIFICATION

E-01,02, 04, 25, 34

E-17, 22, 24

Carburetor type

MIKUNI BSR32SS

Bore size

32 mm

I.D. No

13F0

13F2

Idle r/min.

1 300 ± 100 r/min.

Float height

13.0 ±0.5 mm

Main jet (M.J.)

#115

Jet needle (J.N.)

5C60-3rd

Needle jet (N.J.)

P-0

Pilot jet (P.J.)

#17.5

Pilot air jet No. 1 (P.A.J.1)

#87.5

Pilot air jet No.2 (P.A.J.2)

#140

Throttle valve (Th.V.)

#110

Pilot screw (PS.)

2Vá turns out

turns out

Throttle cable play

2-4 mm (0.08-0.16 in)

Starter plunger cable play

0.5-1.0 mm (0.02-0.04 in)

SERVICING INFORMATION 7-30

CARBURETOR

ITEM

SPECIFICATION

E-03, 28

E-33

Carburetor type

MIKUNI BSR32SS

Bore size

32 mm

I.D. No

13F3

13F4

Idle r/min.

1 300 ± 50 r/min.

Float height

13.0 ±0.5 mm

Main jet (M.J.)

Jet needle (J.N.)

5C65

Needle jet (N.J.)

Pilot jet (P.J.)

Pilot air jet No. 1 (P.A.J.1)

#87.5

Pilot air jet No.2 (P.A.J.2)

#120

Throttle valve (Th.V.)

#110

Pilot screw (PS.)

PRE-SET

Throttle cable play

2-4 mm (0.08-0.16 in)

Starter plunger cable play

0.5-1.0 mm (0.02-0.04 in)

ELECTRICAL _________________________________________________ Unit: mm (in)

ITEM

SPECIFICATION

NOTE

Ignition timing

10°B.T.D.C. at1 300r/min.

Spark plug

Type

NGK: DR8EA

DENSO: X24ESR-U

Gap

0.6-0.7

(0.024-0.028)

Spark performance

Over 8 (0.3) at 1 atm.

Ignition coil resistance

Primary

3-5

terminal-

terminal

Secondary

17-28

terminal-

Plug cap

Ignition coil primary peak voltage

More than 200 V

Generator coil resistance

Pick-up

400-650

Bl-G

Charging

0.1-1.5

Y-Y

Pick-up coil peak voltage

More than 5.0 V

Generator Max. output

210Wat5 000r/min.

Generator no-load voltage

More than 60 V (AC) at 5 000 r/min.

Regulated voltage

13.5-15.0 Vat 5 000 r/min.

Starter relay resistance

3-6

Battery

Type designation

FTX7L-BS

Capacity

12V21.6kC(6Ah)/10HR

Standard

electrolyte S.G.

1.320 at 20°C (68°F)

Fuse size

Main

20A

Headlight

15A

Headlight

15A

Turn signal

15A

Ignition

10A

Taillight

10A

7-31 SERVICING INFORMATION

WATTAGE Unit: W

SPECIFICATION

ITEM

E-01,02, 04,

17,22,25,34

E-24

E-03, 28, 33

Headlight

Position light

Brake light/Taillight

21/5

Turn signal light

(rear)

Front turn signal light/Running light

21/5

Speedometer light

1.7

Neutral indicator light

3.4

Turn signal indicator light

3.4

High beam indicator light

1.7

BRAKE + WHEEL Unit: mm (in)

ITEM

STANDARD

LIMIT

Rear brake pedal free travel

20-30

(0.8-1.2)

Rear brake pedal height

(2.0)

Brake disc thickness

Front

5.0 ± 0.2

(0.20 ±0.01)

4.5

(0.18)

Brake disc runout

Front

0.30

(0.012)

Master cylinder bore

12.700-12.743

(0.4999-0.5017)

Master cylinder piston diam.

12.657-12.684

(0.4983-0.4994)

Brake caliper cylinder bore

33.960-34.036

(1.3370-1.3400)

Brake caliper piston diam.

33.884-33.934

(1.3340-1.3360)

Brake drum I.D.

Rear

130.7

(5.15)

Brake lining thickness

Rear

1.5

(0.06)

Wheel rim runout

Axial

2.0

(0.08)

Radial

2.0

(0.08)

Wheel axle runout

Front

0.25

(0.010)

Rear

0.25

(0.010)

Wheel rim size

Front

16XMT2.50

Rear

15XMT3.00

Tire size

Front

110/90-16 59P

Rear

130/90-15M/C66P

SERVICING INFORMATION 7-32

ITEM

STANDARD

LIMIT

Tire tread depth

Front

1.6

(0.06)

Rear

2.0

(0.08)

SUSPENSION Unit: mm (in)

ITEM

STANDARD

LIMIT

NOTE

Front fork stroke

120

(4.7)

Front fork spring free length

301

(11-9)

Front fork oil level

105

(4.1)

Rear wheel travel

(3.5)

Swingarm pivot shaft runout

0.3

(0.01)

TIRE PRESSURE

COLD INFLATION

TIRE PRESSURE

NORMAL RIDING

SOLO RIDING

DUAL RIDING

kPa

kg/cm2

psi

kPa

kg/cm2

psi

FRONT

175

1.75

175

1.75

REAR

200

2.00

225

2.25

FUEL + OIL

ITEM

SPECIFICATION

NOTE

Fuel type

Use only unleaded gasoline of at least 87 pump

octane or 91 octane or higher rated by the

research method. Gasoline containing MTBE

(Methyl Tertiary Butyl Ether), less than 10%

ethanol, or less than 5% methanol with

appropriate cosolvents and corrosion inhibitor is

permissible.

E-03, 33

Use only unleaded gasoline of at least 87 pump

octane method) or 91 octane or higher

rated by the Research Method.

E-28

Gasoline used should be graded 91 octane or

higher. An unleaded gasoline is recommended.

The others

Fuel tank including reserve

14 L (3.7/3.1

US/Imp gal)

reserve

2.9 L (0.8/0.6

US/Imp gal)

Engine oil type and grade

SAE10W/40, APISForSG

Engine oil capacity

Change

1 300 ml

(1.4/1.1 US/Imp qt)

Filter change

1 400 ml

(1.5/1.2 US/Imp qt)

Overhaul

1 700 ml

(1.8/1.5 US/Imp qt)

Front fork oil type

SUZU

KlforkoilSS-08(#10)

Front fork oil capacity (each leg)

369 ml

(12.5/13.0 US/Imp oz)

Brake fluid type

DOT 4

Prepared by SUZUKI

MOTOR CORPORATION

Motorcycle Service Department

June, 1998

Part No. 99500-32100-01E

Printed in Japan

224

Suzuki Gz250 Users Manual

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