‘SERVICING INFORMATION 8-1 rier em a ea Ue CONTENTS —————— — TROUBLESHOOTING .. CARBURETOR . CHASSIS BRAKES.. ELECTRICAL BATTERY WIRING DIAGRAM. . 8-10 WIRE HARNESS, CABLE AND HOSE ROUTING. 8-13 WIRE HARNESS ROUTING 8-13 WIRING HARNESS ROUTING 8-14 SPEED SENSOR LEAD WIRE ROUTING 815 CABLE ROUTING 8-16 FUEL SYSTEM HOSE ROUTIN 8-17 COOLING SYSTEM HOSE ROUTING 8-19 8 | FRONT BRAKE HOSE ROUTING. 8-20 REAR BRAKE HOSE ROUTING. e2t PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING 8-22 | FUEL TANK SET-UP. 229 SPECIAL TOOLS 8-24 TIGHTENING TORQUE. 8-27 | ENGINE. 827 | CHASSIS 8-28 TIGHTENING TORQUE CHART 8-30 SERVICE DATA .. 8-31{8-2 _SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint ‘Symptom and possible causes Remedy Engine will not start, | Compression too low or is hard to start. | 1. Out of adjustment tappet clearance. Adjust. 2, Wom valve auides or poor seatina of valves. | Repair or replace. 3. Mistiming valves. Adjust. 4, Excessively wom piston rings. Replace. 5. Wom-down evlinder bore. Replace or rebore. 6. Too siowly starter motor cranks. See electrical section. 7. Poor seating of spark plug. Retighten Plugs not sparking Fouled spark plug. ‘Wet spark plug. Defective ignition coil Open or short in high-tension cord, Defective signal generator or ignitor unit. | No fuel reaching the carburetors Clean, Clean and dry. Replace Replace. Replace. 3. Not working tension adjuster. Noise seems to come from clutch Worn splines of countershatt or hub. Wom teeth of clutch plates. Distorted clutch plates, driven and drive. Wom clutch release bearing. . Weakened clutch dampers. | 1. Clogged fue! tank air breather hose. Clean or replace, 2. Clogged or defective vacuum fuel valve. Clean or replace. 9. Defective fuel pump. Replace. 4, Defective carburetor needle valve. Replace, 5. Clogged fuel hose or fuel fier. Clean or replace. Engine stalls easily. | 1. Fouled spark plugs Clean. 2. Defective signal generator or ignitor unit. Replace, 3. Clogged fuel hose. Clean. 4. Clogged jets in carburetor. Clean 5. Out of adjustment tappet clearance. Adjust. Noiey engine. Excessive valve chatter 1. Too large valve clearance. Adjust. 2. Weakened or broken valve springs. Replace. 8. Worn tappot or cam surface Replace. 4, Worn and burnt camshaft journal. Replace. Noise seems to come from piston 1. Worn down piston or cylinders. Replace. 2. Fouled with carbon combustion chambers. Clean. 3. Worn piston pins or piston pin bore. Replace. 4, Worn piston rings or ring grooves. Replace. Noise seems to come from timing chain 1, Stretched chain. Replace, 2. Worn sprockets. Replace, Repair or replace. Replace. Replace. Replace. Replace. Replace the primary driven gear.SERVICING INFORMATION &3 Complaint Symptom and possible causes Remedy Noisy engine. Noise seems to come from crankshaft 1. Due to wear rattling bearings. Replace. 2. Warn and burnt big-ond hoarings Replace, 3. Worn and burnt journal bearings. Replace. 4, Too large thrust clearance. Replace thrust bearing, Noise seems to come from transmission 1. Wom or rubbing gears. Replace, 2. Badly worn splines. Replace, 3. Worn or rubbing primary gears. Replace, 4, Badly worn bearings. Replace, Noise seems to come from water pump 1. Too much play on pump shaft bearing Replace, 2. Worn or damaged mechanical seal Replace, 3. Touches pump case and impeller. Replace, Slipping clutch. 1. Out of adjustment or loss of play clutch control. | Adjust 2, Weakened clutch springs. Replace. 3. Worn or distorted pressure plate, Replace, 4, Distorted clutch plates, driven and drive. Replace. Dragging clutch. 41. Out of adjustment or loss of play clutch control. | Adjust 2. Clutch eprings weakened. Replace. 3, Distorted pressure plate or clutch plate. Replace, Transmission will 1. Broken gearshift cam. Replace. not shift. 2. Distorted gearshift forks. Replace. 3. Worn gearshift cam plate, Replace. Transmission will 1. Broken retum spring on shift shaft. Replace. not shift back. 2, Rubbing or sticky shift shaft. Repair or replace. 9. Distorted oF worn gearshift forks. Replace. Transmission jumps | 1. Wom shifting gears on driveshaft or countershaft. | Replace. ‘out of gear. 2, Distorted or worn gearchift forks. Replace. 3. Weakened stopper spring on gearshift stopper. | Replace. 4, Worn gearshift cam plate. Replace. Engine idles poorly. | 1. Out of adjustment tappet clearance, ‘Adjust. 2. Poor seating of valves. Replace or repair. 3. Detective valve guides. Replace. 4. Worn tappet or cam surface. Replace. 5. Too wide spark plug gaps. Adjust or replace, 6. Defective ignition coil. Replace. 7. Defective signal generator or ignitor unit. Replace, 8. Out of adjustment in carburetor float-chamber | Adjust. fue! level. 9. Clogged jets or imbalance of carburetors. Clean or adjust. 10. Defective fuel pump. Replace84 SERVICING INFORMATION Complaint ‘Symptom and possible causes Remedy Engine runs poorly | 1. Weakened valve springs. Replace, in high speed range. | 2. Worn camshafts. Replace, 3. Valve timina out of adiustment. Adiust. 4. Too narrow spark plug gaps. Adjust. 5. Ignition not advanced sufficiently due to poorly | Replace ignitor unit. working timing advance circuit. 6. Defective ignition coil Replace. 7. Defective signal generator or igntior unit. Replace. 8. Too low float-chamber fuel level. Adjust. 9. Clogged air cleaner element. Clean. 10. Clogged fuel hose, resulting in inadequate fuel_| Clean and prime. ‘supply to carburetors, 11. Defective fuel pump. Replace. Dirty or heavy 1. Too much engine oil in the engine. ‘Check with inspection exhaust smoke. window drain out excess oil 2. Worn piston rings or cylinders. Replace 3, Worn valve guides. Replace 4. Scored or scuted cylinder walls. Rebore. 5. Worn valves or stems. Replace. 6. Defective stem seal Replace, 7. Worn oil ring side rails. Replace, Engine lacks power. | 1. Loss of tappet clearance. Adjust. 2. Weakened valve springs. Replace. 3. Out of adjustment valve timing, Adjust. 4, Wom piston rings or cylinders. Replace, 5. Poor seating of valves. Repair. 6. Fouled spark plug. Clean or replace, 7. Incorrect spark plug Adjust or replace. 8. Clogged jets in carburetors. Clean 9. Out of adjustment float-chamber fuel level. Adjust. 10. Clogged air cleaner element. Clean 11. Loose carburetor balancing screw... Retighten. 42. Sucking air from intake pipe. Retiahten or replace, 13. Too much engine oil. Drain out excess oil 14, Defective fuel pump. Replace. Engine overheats. | 1. Heavy carbon deposit on piston crowns. Clean, 2. Not enough oil in the engine. ‘Add oil, 3. Defective oll pump or clogged oll circuit. Replace or clean. 4, Too low in float chambers fuel level. Adjust. 5. Sucking air from intake pipes. Retighten or replace. 6. Use incorrect engine oll. Change. 7. Defective cooling system. See radiator section,SERVICING INFORMATION. 6-5 RADIATOR ‘Complaint ‘Symptom and possible causes Remedy Engine overheats. | 1. Not enough cooling water. ‘Add coolant. 2. Clogged with dirt or tradhes radiator core. Clean, 3, Erratic thermostat, stuck in closed position, Replace. 4. Faulty cooling fan. Repair or replace. 5, Detective thermo-switch. Replace. 6. Clogged water passage Clean. 7. Air trapped in the cooling circuit. Bleed out ai 8. Defective water pump. Replace. 9. Use incorrect coolant. Replace Engine overcools. | 1. Erratic thermostat, stuck in fullopen position. | Replace, 2. Defective thermo-switch. Replace. . Extremely cold weather. Put on the radiator cover. CARBURETOR ‘Complaint ‘Symptom and possible causes Remedy Trouble with starting.| 1. Clogged starter jet. Clean. 2. Clogged starter pipe. Clean. 3. Air leaking from a joint between starter body | Check starter body and carburetor. and carburetor for tighteness, adjust and replace gaskot 4. Air leaking from carburetor’ joint or vacuum | Check and adjust. hose joint, Not operation properly starter plunger. Check and agjust. Idling or low-speed trouble. . Clogged or loose pilot jet, pilot air jet. Air leaking from carburetor’ joint, bacuum hose joint, or starter. . Clogged pilot outlet or bypass. Not fully closed starter plunger. Check and clean. Check and adjust. Check and clean, Check and adjust. Too high or low fuel level. Defective fuel pump. Medium-or high 1. Clogged main jet or main air jet. Check and clean. ‘speed trouble. 2. Clogged needle jet. Check and clean, 3. Not operating properly throttle valve. Check throttle valve for operation. 4, Clogged fuel filter Check and clean. Overflow and fuel | 1. Worn or damaged needle valve. Replace. level fluctuations. | 2. Broken spring in needle valve. Replace, 8, Not working property float. Check and adjust. 4. Foreign matter has adhered to needie valve. | Clean. 5. 6 ‘Adjust float height. Replace.86 _ SERVICING INFORMATION CHASSIS. Complaint ‘Symptom and possible causes Remedy Heavy steering. 1. Overtightened steering stem nut. ‘Adjust. 2 Rrnken hearing in staaring stam Renlaca 8. Distorted steering stem Replace, 4, Not enough pressure in tires Adjust. Wobbly handlebars. | 1. Loss of balance between tight and left front forks. | Replace. 2. Distorted front fork. Repair or replace. 3. Distorted front axle or crooked tire. Replace. 4, Worn bearing/race in steering stem. Replace, Wobby front wheel. | 1. Distorted wheel rim, Replace. 2, Worn front wheel bearing, Replace. 3. Defective or incorrect tre. Replace. 4, Loose axle, axle nut or axle pinch bolts. Retighten. 5. Incorrect front fork oil level Adjust. Front suspension | 1, Weakened springs. Replace. too soft. 2. Not enough fork oil Replenish 98. Wrong weight tank oil. Replace, Front suspension | 1. Too viscous fork cil Replace. too stitt. 2, Too much tork oll Drain excess oil 3, Bent front axle, Replace. Noisy front 1. Not enough fork oil Replenish suspension. 2. Loose bolts on suspension. Retighten. Wobbly rear wheel. | 1. Distorted wheel rim. Replace, 2. Wor rear wheel bearing or swingarm bearings. | Replace. 2. Defective or inoorrost tir. Roplace. 4, Wom swingarm and rear cushion related bearings. | Replace. 5. Loose nuts or bolts on rear suspensions. Rear suspension 1. Weakened shock absorber spring. Replace too soft. 2. Improperty set rear suspension adjuster. Adjust. 8. Leakage oil of shock absorber. Replace, 4, Leakage gas of shock absorber. Replace. Rear suspension 1. Improperly set rear suspension adjuster. Adjust. too stiff. 2. Bent shock absorber shaft Replace, 8. Bent swingarm Replace, 4, Wom swingarm and rear cushion related bearings. | Replace. Noisy roar 1. Loose nuts or bolts on rear suspension. Rotighten. ‘suspension. 2. Wom swingarm and rear cushion related bearings. | Replace.BRAKES SERVICING INFORMATION. 8-7 ‘Complaint ‘Symptom and possible causes Remedy Insufficient brake power. gaepn Leakage of brake fluid from hydraulic system. Worn pado. il adhesion of engaging surface of pads. Wom disc. Ar in hydraulic system. Repair or replace. Replace. Clean disc and pads. Replace, Bleed arr Brake squeaking. Carbon adhesion on pad surface. Tilted pad. . Damaged wheel bearing, . Loosen front-wheel axle or rear-wheel axle. Worn pads. Foreign material in brake fluid Clogged return port of master cylinder. Repair surface with sandpaper. Modify pad fitting or replace. Replace. Tighten to specified torque. Replace. Replace brake fluid. Disassemble and clean master cylinder. Excessive brake 1. Air in hydraulic system. Bleed air lever stroke. 2. Insufficient brake fluid. Replenish fluid to spe- Gilied level; bleed air 3, Improper quality of brake fluid. Replace with correct flu. Leakage of brake 1. Insufficient tightening of connection joints. Tighten to specified ‘fluid torque 2. Cracked hose, Replace, 8. Worn piston and/or cup. Replace piston and/or up, Brake drags. Rusty part. 2. Insufficient brake lever or brake pedal pivot lubrication. Clean and lubricate. Lubricate.88 SERVICING INFORMATION ELECTRICAL ‘Complaint ‘Symptom and possible causes Remedy No sparking or poor | 1. Detective ignition coil Replace, sparking 2 Retective spark plugs Replace 3. Defective signal generator or ignitor unit. Replace, Too lean mixture. Spark plug soon 1. Mixture too rich Adjust carburetors. become fouled with | 2. Idling speed set too high. Adjust carburetors, carbon. 3. Incorrect gasoline. Change. 4. Dirty element in air cleaner. Clean, 5. Too cold spark plug. Replace with hot type plugs. ‘Spark plugs become | 1. Wom piston rings Replace, fouled too soon. 2. Wom piston or cylinders. Replace, 3, Excessive clearance of valve stem in valve Replace. guides. 4, Wom stem oil seal Replace. ‘Spark plug electrod- | 1. Too not spark plugs. Replace with cold type es overheat or burn. plugs. 2. Overheated the engine. Tune up. 3. Loose spark plugs. Retighten, 4 Adjust carburetors. Generator does not charge. pen or short lead wires, o loose lead connections. Shorted, grounded or open generator coils. Shorted or punctured regulator/rectifiers. Repair or replace or retighten. Replace. Replace. Generator does charge, but charging Lead wires tend to get shorted or open-circuited fr loosely connected at terminals, Repair or retighton, regulator/rectiter. Poorly grounded regulatorirectfer. rate Is below the 2. Grounded or open-circuited stator coils or Replace. specification. generator. 3, Defective regulator/rectitier. Replace. 4, Detective cell plates in the battery. Replace the battery. Generator 1. Internal short-circuit in the battery. Replace the battery. overcharges. 2. Damaged or defective resistor element in the | Replace. Clean and tighten ground connection. Unstable charging. - Lead insulation frayed due to vibration, resulting in intermittent shorting. Repair or replace. starter motor. Defective starter relay/starter interlock switch. 2. Internally shorted generator. Replace. 3. Defective regulator/rectifier. Replace. Starter button is not | 1. Run down battery. Repair or replace. effective. 2. Defective switch contacts. Replace. 8. Not seating properly brushes on commutator in | Repair or replace. Replace.SERVICING INFORMATION. 8-9 BATTERY ‘Complaint ‘Symptom and possible causes Remedy “Sulfation”, acidic | 1. Cracked battery case. Replace the battery. white powdery sub- | 2. Battory has boon lett in a run-down condition for | Replace the battery. stance or spots on a long time. surface of cell plates. Battery runs down | 1. Not correct the charging system. Check the generator, quickly. requlator/rectifier and circuit connections and make necessary adjustments to obtain specified charging operation. 2. Cell plates have lost much of thelr active Replace the battery, material as a result of overcharging. and correct the charg- ing system. 8. A short-circuit condition exists within the battery. | Replace the battery 4, Too low battery voltage. Recharge the battery fully 5. Too old battery. Replace the battery. Battery “sulfation 4. Tou Tow uF tue hhiyts aryiny rate. Replace the battery. (When not in use batteries should be checked at least once a month to avoid sulfation.) 2. Left unused the battery for too long in cold Replace the battery, if ate. badly sulfated. Battery discharges | Dirty container top and sides. Clean. too rapidly.810 _ SERVICING INFORMATION. WIRING DIAGRAM (FOR U.S.A. AND CANADA MODELS)SERVICING INFORMATION 811 (FOR E-24 MODEL) Hnileey HERE] daseesscoeiss?: dads SBoebisiser dieser{8-12 _ SERVICING INFORMATION (FOR E-02, 04, 17, 18, 22, 25 AND 34 MODELS) i 3 > BESZERERSSSSSSSSLESESLEE See = ont |i ing: @s0—SERVICING INFORMATION 8-13 WIRING HARNESS, CABLE AND HOSE ROUTING WIRE HARNESS ROUTING came icing narnoce 2 Requatoviectiior Batiery © gnal gana [Sigal genset ~ [Fear brake ight ewich ass through the saree moto lead wir and battery Sead came ciame vio under he rama cramp |Oi pressure switen lamp Ol ite nares games go] (Wena mace Peeters | andebar sw [Cosing an emma-anicR clamp ‘onto wlan moar a lame8:14 SERVICING INFORMATION WIRE HARNESS ROUTING Newtralinaicator ight switch ‘octal icator gt switchSERVICING INFORMATION 8-15 SPEED SENSOR LEAD WIRE ROUTING temp —_8-16 _ SERVICING INFORMATION. CABLE ROUTING erge> mony rae ino 21m pe0| Bs uoRU) ‘opn6 ovo 04 Jo opisu passed onus 99 vain ou pue age: J0u8 24, semneee st eeseno — sorte y — a cog onn \— dug Loasan eae eee tareaee \ ae sevens ‘p(6 oy ojo ops rossed 9 snul sjge> awoa SULSERVICING INFORMATION 817 FUEL SYSTEM HOSE ROUTING 001 10 UO ‘orl ons8:18 SERVICING INFORMATION. ajge0 nase dois apni, sovesnesboSERVICING INFORMATION 8-19 COOLING SYSTEM HOSE ROUTING vo —2pysunop 206) srs ee oxo pus ou - yen 86“ susoploon; isu “981003 doajfsnwy “et J8U9D eu RoR jopus eal POU OR duIRD eu, POUORsod aq Iss Seven a my een ue 9 ‘eprsumcp rue even 2m 8 au ano ie so Sune cy ms Lg seeb uanue E=® ra orem pe anosoy8.20 SERVICING INFORMATION FRONT BRAKE HOSE ROUTINGSERVICING INFORMATION 821 REAR BRAKE HOSE ROUTING seusen 102 voUn asoy oMeIa : or posed oq ym osoy avg \ (D ‘ower ou ya 804 | ‘ep rem ue) ‘ua pur onou XD sonesor ay dey —\ any aus 43 904 x 1 du og ues) ew oma ZO 204 U9 s0Koso4 i pn 5204 ‘due oun p pue eu \ ue suesou822 SERVICING INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING (FOR CALIFORNIA) PAIR valveSERVICING INFORMATION 823, FUEL TANK SET-UP CLL8:24 SERVICING INFORMATION SPECIAL TOOLS 9900-06108 2000-061 (98800-06108 ‘08000-09008 (9800-20102 107 ‘Shap rngplers ‘Shap ring pers Snap ing lors Impact driver set Verrier calipers ‘9900.20208 (09000.20206 Micometer Micrometer Dialgauge (75=100 mm) (0-25mm) Gyancargaugeset | (100%, men Diatgauge 9800-21504 (s8dmm.10mm) | Magnet stand Sire cep gouge ‘Vbock (100 mm) Qq a, 9800-22408 15-63310 gaan zone ‘Sinallbore gan 13800-25008 wanvzors Compression gauge Prasigauge (i835 mm Muticircuittesterset__| Conrodholder adapter Q . € SA Sa “O op913-13121 cao13-so121 ‘oumalbearog cgo1s-70210- 2991540610 Caruriorbaiaeerset | Oisesl remover omovernstalr Bearinginstaset__| Oviiter ranch[SERVICING INFORMATION 825 ts eats 501574520 ce1s.74590 ooots.77a00 eresiio Tprossure gauge | Olpressure gau Meter or high 2916-10011 Compressiongauge | Fofersewesseae | Sagotor "| pressure) awe lapper set ovor6-14510 ovet6-4521 201620640 0991620690 avo spring Vabe spring cooteatitt Sal piot Wate seat cutter head compress Conprensoratactnnet | Vaiwrswat cuter set | (NOD) wes, X ovstesser0 9916-34580 ovet6-48210 opor6.se54e VVahe gudereamer | Vatvegudereamer | Vaive guide p96 53200 onmor hone ee (oem omectnetalor ‘Atachment IN 1e) 09017-47010 9017-62490 9000-13120 seotepsstt Vacuum pump ga am chain fnsion rankease separating | 0292085740 Tweezers Nacuumpump gauge | Camchatension | fear Noas® S830 | Cachsleevehubhoter germ lomnewe |ommone forme, ormeme ~O Bearingremoverset | Oilseal guide Bearinginstalerset | Beannginstalerset | Tobit JT40H826 SERVICING INFORMATION S © S ceowo.4e11 fom coea0 1840 ose 500 Seemngsiomnt | Samer aductcack eee eariii wench Simarme (09940-14990 ceeso-so8es Ergremouring st | o2o1otsc0 ceot0 9801 Frntonotsea! | oxe4osov20 Erpoernaargrecc | Prac see rons Sango 09941-34513 Te 09041-54911 09041-74911 eat ‘\ Seung stotng race ; Scampouorece | Seeing bout ooesset installer set Wheel bearngromover| remover etalon Forkoillevel gauge G aN se-10760 Prete gage Nore: When order the special tool, please confirm whether itis available or not.SERVICING INFORMATION 827 TIGHTENING TORQUE ENGINE TEM Nm kgt-m Ioett ‘cylinger nead cover bom 14 14 10 Spark plug 14 14 8.0 ‘Camshaft journal holder bolt 10 1.0 7.0 Cam chain tension adjuster bolt a 08 6.0 ‘Cam chain tension adjuster mounting bolt 10 10 70 ‘Cam chain guide bolt 10 1.0 7.0 ‘Cam chain tensioner mounting bolt 10 1.0 7.0 Cylinder head bolt [M10] (initia) 25 25 18.0 (Final) 42 42 30.5 Cylinder head bolt [M6] 40 1.0 7.0 Cylinder head side bolt 14 14 1.0 | cylinder nut M8] 40 1.0 7.0 Water drain bott 13 13 95 Impeller securing bolt 13 13 95 Clutch sleeve hub nut 50 5.0 36.0 Giuton spring set bott 55 0.55 40 Oil plate bott 10 1.0 7.0 Oil pressure regulator 7 27 19.6 Oil strainer plate bolt 10 1.0 70 Primary drive gear bolt 70 7.0 50.5 Generator cover plug "1 1 8.0 Valva timing inspection nig 2a DA Ty Generator rotor bolt 120 12.0 87.0 Starter clutch bolt 25 25 18.0 Generator stator set bolt 40 1.0 70 Signal generator set bolt 55 0.55 40 Gerarshift cam stopper bolt 10 1.0 70 Gearshift cam stopper plate bolt 10 1.0 70 Gearshift arm stopper bolt 23 23 165 Oil pressure switch 14 14 10.0 Crankcase bolt [M6] 4 14 8.0 [M8] 26 26 19.0 Generator cover Doit (M6) 10 1.0 7.0 Clutch cover bolt [M6] 10 1.0 7.0 ‘Water pump case screw 45 0.45 398.28 SERVICING INFORMATION ITEM Nm kgf-m_ Ib-ft on gallery plug i16) 3° 38 23.5 [M8] 18 18 13.0 oo) 55 055 40 Oil drain plug 24 24 15.0 Picton cooling oil jat alt 10 10 70 Oil pump mounting bolt 8 0.8 6.0 Conrod bearing cap bolt (Initial) 35 35 25.5 inal) 67 67 485 Exhaust pipe bolt 23 23 165 Grankcase bearing retainer screw 8 08 60 Muffler mounting nut 23 28 165 Muffler joint nut 23 23 16.5 Oil pipe stopper screw 8 08 6.0 Engine sprocket nut 145 14.5 105 Engine mounting pinch bolt 23 23 16.5 Engine mounting bolvnut iwit2] 93 93 ors (M10) 55 55 400 Engine mounting Hust adjuster [Center] 10 10 7.0 (Rear Lower] 10 10 7.0 Engine mounting thrust adjuster [Center] 45 45 22.5 eck) [Rear Lower] 45 45 32.5 Goaling fan therme-switch 3 13 35 Engine coolant temperature switch 10 1.0 7.0 CHASSIS. ITEM Nm kgf-m Ib-ft Steering stem head nut 65 65 47.0 Front fork upper clamp bolt 23 23 16.5 Front fork lower clamp bolt 2 23 165 Front fork cap bolt 23 23 165 Tront fork damper rod bolt 30 30 215 Front axle 65 65 47.0 Front axle pinch bolt 23 23 165 Handlebar clamp bolt 23 23 16.5 Handlebar holder nut 45 45 325SERVICING INFORMATION 8-29 ITEM Nm kgt'm Ibeft Front brake master cylinder mounting bolt 10 1.0) 0 Front brake caliper mounting bolt Ey 39 28.0 Brake hose univ bolt 2 28 105 Clutch holder mounting bott 10 1.0 7.0 ‘Air bloeder valve 75 0.75 55 Brake disc bolt (Front and Rear) 23 23 165 Rear brake caliper mounting bolt 26 26 19.0 Rear brake caliper housing bolt 30 3.0 215 Rear brake master oylinder mounting bolt 10 1.0 7.0 Rear brake master cylinder rod lock nut 18 18 13.0 Front footrest bracket mounting bolt 23 23 165 Front footrest bolt 39 39 | 280 ‘Swingarm pivot shaft 15 15 11.0 ‘Swingarm pivot shaft nut 100 10.0 725 ‘Swingarm pivot shaft lock nut 90 9.0 65.0 Torque link nut (Front and Rear) 35 35 25.5 Bene aa mounting boltinut 5 50 = Rear cushion leverifod mounting nut 78 78 56.5 Rear axle nut 65 65 470 Rear sprocket nut 60. 60 43.58:30 _ SERVICING INFORMATION. TIGHTENING TORQUE CHART For athar bolts and nuts listed previously, refer to this chart: Bott Diameter ‘Conventional or “4” marked bolt "7" marked bolt ® (mm) Nm kgtm Tot Nm kofm Tost 4 15 0.15 1.0 23 0.23 15 5 3 03 2.0 45 0.45 3.0 6 55 055 40 10 10 70 8 13 13 95 23 23 165 10 29 29 21.0 50 5.0 36.0 12 45 45 32.5 85 85 615 14 6 65 470 135 13.5 97.5 16 105 105 76.0 210 21.0 152.0 18 160 16.0 115.5 240) 24.0 173.5 Conmentonal bot “4° mathe bot “7 marked botSERVICING INFORMATION 8-31 SERVICE DATA VALVE + GUIDE Dee ITEM STD/SPEC. LIMIT Vai dam im oy 255 ~ Es fal — Valve clearance IN. 0.1-0.2 (When cold) (0.004 ~ 0.008) _ 2-03 es (0,008 - 0.012) — - Valve guide to valve stem a one = 97, clearance 0008 — al A 0.030 — 0.057 : (0.0012 ~ 0.0022) —_ Valve guide 1b. IN. BEX oiirre = 0176) —_ Valve stem O.D. IN 4.465 — 4.480 “ (0.1758 — 0.1764) — 4.455 4.470 x (0.1754 — 0.1760) — Valve siem defiecion mire os _ Valve stem runout niven ‘oes Valve head thickness ner ay Valve seat wish ntreR (ede bea Valve head radial runout A cB, ‘Valve spring free length 36.8 (IN. & EX.) INNER (1.45) 39.8 OUTER (1.57) Valve spring tension 4.2 - 4.8 kof -~ (N.&EX) INNER (8.26 ~ 10.58 fos) — at length 29.9 mm (1.18 in) 17.0 - 19.6 kg ourer (67.48 ~ 43:21 ibs) — at length 33.4 mm (1.31 in)8:32 _ SERVICING INFORMATION CAMSHAFT + CYLINDER HEAD Unit: mm (in) TEM ‘STOIEPEC. car ‘Cam height in 35.480 - 35.530 35.18 (1.397 - 1.399) (1.385) = 33.480 83.630 33.18 (1.318 - 1.320) (7,306) ‘Camshaft journal oil clearance 0.082 — 0.066 0.150 IN. BEX, (ania — anna) (o.ansa) ‘Camshaft journal hoider LD. iter ieania em eaaees ‘Camshait journal OD. NAEX. eueameal ‘Camshaft runout mr ean ‘Cam chain pin (at arrow “3*) ith pin Cylinder head distortion 0.05 (9.002)8.34 SERVICING INFORMATION CONROD + CRANKSHAFT Unit: mm (in) TEM ‘STDISPEC. TMT Conrad small end ID. 20.010 — 20.018 20.040 (0.7878 - 0.7881) (0.7890) Conrad big ond tide clearance 0.170 — 0.320 O58 (0.0067 0.0126) (0.02) Conrod big end width 20.95 — 21.00 (0.825 - 0.827) — ‘Crank pin width 42.17 — 42.22 (1.660 ~ 1.662) — ‘Conrod big ond oil clearance 0.092 — 0.056 0.080 (0.0013 ~ 0.0022) (0.0031) Crank pin O.D. 37.976 — 38.000 (4.4951 - 1.4960) — ‘Crankshaft journal oil clearance (0.008 — 0.035 0.080 (0.0003 - 0.0014) (0.0031) ‘Crankshaft journal 0.0, 41.985 — 42.000 (1.6529 — 1.6535) — Crankshaft thrust bearing 1.925 — 2.175 thickness (0.0758 - 0.0856) — Crankshaft thrust clearance 0.050 = 0.110 (0.0020 - 0'0043) —_ Crankshaft runout 0.05 (0.002) OIL PUMP TEM STDISPEC. iM Gil pressure (at 60°C, 140°F) ‘Above 200 kPa (2.0 kgf/om®, 28 pai) Below 600 kPa (6.0 kgf/om?, 85 psi) — at 3 000 r/min CLUTCH Unit: mm (in) TEM STDISPEC. LIMIT Clutch cable play 40-15 (04-06) = Glitch release serew 174 turfs) back —= Drive plate thickness Nat 2.92 ~ 3.08 2.62 (0.115 ~ 0.121) (0.103) ‘3:42 — 3.58 3.12 oo (0.135 = 0.141) (0.423) Drive plate claw width No.t 15.9 - 160 15.1 &No2 (0.626 - 0.630) (0.59) Driven plate distortion 0.10 (0.004) Clutch spring free length BAO 56.0 (2.32) (2.20)SERVICING INFORMATION 8:35, TRANSMISSION + DRIVE CHAIN Unit: mm (in) TEM ‘STDISPEC- cM Primary reduction ratio 2.088 (71/34) — Final reduction ratio ‘SV650S 2.933 (44/15) — ‘SV650 3.000 (45/15) — Gear ratios Low 2.461 (92/13) — 2nd 4.777 (32/18) — 3rd 4380 (29721) — 4th 1.125 (27/24) — 5th 0.961 (25/26) — Top 0.851 (23/27) — Shift fork to groove clearance 01-03 08 (0.004 — 0.012) (0.020) Shift fork groove width 35-56 (0.217 - 0.220) _— Shift fork thickness 33-84 (0.209 = 0213) Drive chain Type DIDS25V8 =_—_ Tinks |_SV650 1140 Links — SV650S 708 Links — 20-pitch 319.4 length (12.57) Drive chain slack (on side-stand) 20-30 (0.79 = 1.18) — Gearshift lever height ‘avanos a8, 55-60 a (22-24) —_ THERMOSTAT + RADIATOR + FAN + COOLANT minum radiator, mixed with distilled water only, at the ratio of 50:50. TEN SIDSPEC. cm “Thermostat valve opening 82°C temperature APPIOX. (479 6°F) Thermostat VaNve i Cver BO MUST Mn) at OU OTT) — Engine coolant temperature 115°C ‘switch operating temperature [OFF > ON APPIOX. (29°F) (on OFF] Apo 8S — Radiator cap valve opening 95 — 125 KPa pressure (0.95 - 1.25 kotlem!, 13.5 - 17.8 psi) Cooling fan thermo-switch 26% operating temperature JOFF — ON APPIOX. (004.8°F) oC (ON > OFF| ADPFOX. (195 o°F) -= Engine coolant type Use an anti-freeze/coolant compatible with alu- Engine coolant including reserve | Reserve ‘Approx, 250 mi tank side (0.201022 US/imp at) Engine ‘Approx. 1 350 mi side (1.43/1.19 US/Imp qt)8:96 SERVICING INFORMATION CARBURETOR STDISPEG. we E02, 04, 17, 22, 24, 25, 34 £03, 28 ‘Carburetor type MIKUNI BDSR39 < Bore size ‘39 mm = 1D. No. 20F0 20F2 Idle cmin 1300 = 100 rimin « Fuel level 769 0.5 mm (0.68 + 0.02 in) © Float height 7.0 = 0.5 mm (0.28 0.02 in) < Main jet (MJ) #197.5 #375 Jet needie (WN) BESB-54-2 Bea 52 Needle jet (NJ) P-0 POM. Throttle valve hv.) #95 = Pilot jot (Ps) HS we Pilot screw (PS.) | PRE-SET (2% turns back) PRE-SET (3 tums back) Throttle cable play 2.0 ~ 4.0 mm (0.08 - 0.16 in) © CARBURETOR STDISPEG. wi) E33 E22 (U-Type) Carburetor type MIKUNI BDSASS © Bore size 39mm < LD. No. 20F4 20F5 Ile min 1300 = 100 rfmin « Fuel level 76.9 0.5 mm (0.68 + 0.02 In) < Float height 7.0 = 0.5 mm (0.28 0.02 in) < Main jot (a) #575 #375 Jet needle WN) BEAS-54 GES6-54-2 Needle jet (.J.) F-OM. P-0 Throttle valve Ch. #95 < Pilot et (Ps) #1 HS Pilot screw (PS) PRE-SET PRE-SET (3% tums back) Throttle cable play 2.0 — 40 mm (0.08 — 0.16 in) © CARBURETOR ‘STOSPEC. Tem Esa Carburetor type MIKUNI BDSRSS Bore size 39mm 1D. No. 20F3 Tale rimin 1300 = 50-rimin Fuel level TEE 05 mm (0.68 = 0.02 in) Float height 7.0 = 0.5 mm (0.28 = 0.02 in) Main jet #1375 Jet needle GE36-54-2 Needle jet P2 Throttle valve #95 Pilot jet #15 Pilot screw PRE-SET (2%4 tums back) Throttle cable play 2.0 — 4.0 mm (0.08 - 0.16 in)SERVICING INFORMATION 837 ELECTRICAL TEM ‘STDISPEG. NOTE Firing order 1-2 ‘Spark plug — NGK: CR8E DENSU: U24ESH-N 07-08 mm Gap (0.028 - 0.031 in) ‘Spark performance (Over 8 mm (0.3 in) at 1 atm. Signal coll resistance 140 — 230 2 ‘Signal coil peak voltage More than 3 V Ignition coil resistance Terminal ~ 9 Primary 35-559 pone Secondary 20-81 kA Pug cap = ignition col primary peak voltage More than 150V Generaior coil resistance 02 - 0.55 0 Generator Max. output ‘Approx. 300 W at 5 000 r/min Generator no-load voltage Gane ig More than 70 V (AC) at § 000 r/min Foegulated volage 13.5 — 15.0 Vat O00 rimin Starter relay resistance 3-60 Battery |__ Type designation YTI2A-BS Capacity 72.360 KC (IUARYTORR Fuse size HI 15A, Headlight 15 1h Signal TDA, ignition 108 Meter 104. ain 0A WATTAGE PEC. SV6505 SVE50 bie) uz, 03,24, | The omer | 03,24, | The omer 28, 33 countries 28,'33 countries Headlight HI 45 W x2 55W cow © Lo a5Wx2 55W 55W < Parking or position light SW < SW Brake lightTailight 215 Wx2 © © € “Turn signal light 2iW © © License light SW © < ‘Speedometer ight OB4WxS < T7Wx2 = “Turn signal indicator light 3W © 7 © ‘High beam indicator light, 17W © € © ‘Neutral indicator light 17W © © © Oil pressure indicator light 1.7W © ©{838 _ SERVICING INFORMATION BRAKE + WHEEL Unit: mm (in) Tem STDISPEC. Pd Rear brake pedal free travel 20-30 (0.8 - 1.2) Rear bake peval height ‘99-09 (2.17 - 2.56) Brake disc thickness 45 4.0 Front (0.10) (0.16) 5.0 45 oe (0.20) (0.18) Brake UU runout us (0.012) Master oylinder bore 15.870 - 15.913 be ont (0.6248 — 0.6265) 12,700 12.743 peer (0.5000 = 0.5017) Master cylinder piston diam: 15.827 ~ 15.654 po (0.6231 - 0.6242) 12.657 — 12.684 Rear (0.4983 — 0.4994) Brake caliper cylinder bore 30.230 - 30.306 ce Front (1.1902 ~ 1.1931) —_— 36.180 — 36.256 eet (1.5031 - 1.5061) Brake caliper piston diam. — 30.150 ~ 30.200 (1.1870 — 1.1090) — 38,098 — 38.148 Beat (1.4999 — 1.5019) Brake fluid ype DoT 4 ‘Wheel rim runout A 2.0 Axial — (6.08) 20 Radial — (0.08) ‘Wheel rim size Front 417. x MT3.50 Rear 17x MT4.50 — Wheel axle runout 025 Front (or) Rear — oeSERVICING INFORMATION 8:39 TIRE Unit: mm (in) TEM STD/SPEC. LiMi Gald inflation tire pressure — 225 KPA, (Solo riding) (2.25 kgilem, 33 psi) 250 KPA, Rear (2.50 kgt/cm?, 36 psi) Gold inition tre pressure a 225 KPa, (Dual viding) (2.25 kyllem, 38 psi) — 250 KPa Gal (2.50 kgticm?, 36 psi) Tie size Front 20/60ZR17 (55W) — Rear 60160217 (69W) — Tire pe Front METZELER: MEZ4 FRONT — Hear METZELEH: MEZ4 — Tire tead depth 08 (0.03) [Recommend depth] Front (1.6 (0.06) 0.8 (0.03) Rear (2.0 (0.08)} SUSPENSION Unit: mm (in) TEM STDISPEC. LIMIT Front fork stoke 730 G1) Front fork spring free length 314.6 308 (i288) (12.49) Front fork ol evel (without spring, 702 inner tube fully compressed) "| £09: 39 (4.02) 104 Others ay) Front fork oll ype SUZUKI FORK OL G10 (#10) jor equivalent fork ofl Front fork oll capacity 491 mi {each leg) ese (166/173 US/mp 02) 469 mi Others (16.5/17.2 USimp 02) Rear shock absorber spring | SVB50S a7 — adjuster "SV650 2 = Rear wheel travel 125 (4.9) Swingarm pivot shat runout 03 (0.01)840 SERVICING INFORMATION FUEL + OIL SIDISPEG. NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane (24M) 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 corro- sion inhibitor is permissible. £-03, 33 Tie anly inlaadadt gasoline af at least A7 pump octane (8!) or 91 octane or higher rated by the research method. Gasoline used should be graded 91 octane or higher. An unleaded gasoline is recommended. E28 The others Fuel tank capacity 15 L (4.0/3.3 US/Imp gal E33 16.L (4.2/3.5 US/Imp gal) ‘The others Engine oll type SAE 10W/40, API SF or SG Engine oil capacity Change (2.4 Ooh ad Fier change! (252.1USimp a) Overnaul (ane tein a)