FORWARD The SUZUKI RG 150 E/ES has been developed as a new generation motorcycle to the RG-models. It is packed with highly advanced design concepts including a liquid cooled engine, a crankcase reed valve, a Automatic Exhaust Timing Control (A.E.T.C.) a Digital C.D.1. ignition system a link type rear suspention. Combined with precise control and easy the RG 150 E/ES provides excellent performance and outstanding riding comfort. handling This service manual has been produced primarily for experienced mechanics whose job is to inspect, adjust, repair and service SUZUKI motorcycle. Apprentice mechanics and “do it yourself” mechanics will also find this manual to be an extremely useful guide. The AG 150 E/ES, manufactured specifications, is the main subject matter of this However, the RG 150 E/ES machines distributed in your country might differ in minor respects from the standard-specification and, it they do, itis because some minor modifications (which are of no consequence in most cases as far as servicing is concemed) had to be made to comply with the statutory requirements of your country. to standard ‘manual. This manual contains up-to-date information at the time of its issue. Later made modifications and changes will be explained to each SUZUKI distributor in rospective markets, to whom you are kindly requested to make query about updated information, it any. GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE AND TUNE-UP PROCEDURE ENGINE COOLING SYSTEM FUEL AND LUBRICATION SYSTEM ELECTRICAL SYSTEM CHASSIS SERVICING INFORMATIONVIEW OF RG 150 Ef a7 Rae) et V ae) CONTENTS VIN AND SERIAL NUMBER LOCATIONG..... FUEL, OIL AND COOLING SOLUTION RECOMMENDATIONS... BREAKING-IN PROCEDUREG...... SPECIAL MATERIALS. PRECAUTIONS AND GENERAL INSTRUCTIONS... SPECIFICATIONS ...1-1 GENERAL INFORMATION VIN AND SERIAL NUMBER LOCATIONS ‘The frame serial number or V.I.N.(Vehicle Identification Number) (@) is stamped on 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 and special service information, FUEL, OIL COOLING SOLUTION RECOMMENDATIONS FUEL Gasoline used should be graded 91 octane or higher. An unleaded gasoline is recommended. ENGINE OIL Use SUZUKI CCI Super oll. They are formulated to give best engine performance with least combustion chamber deposits, east Preignition, maximum spark plug life and best lubrication. If they are not available, a good quality TWO-STROKE OIL (non-diluent type) should be used TRANSMISSION OIL Use a good quality SAE 20W/40 multi-grade motor oil FRONT FORK OIL Use fork oll # 10. 99000-99044-1G SAE 10 OR SAE 5 W/20 BRAKE FLUID...DISK BRAKE [Specification and | SUZUKI BRAKE FLUID classification OR DOT 3, DOT 4COOLING SOLUTION Use an antifreeze & Summer coolant compatible with aluminum radiator, mixed with distilled water only, at ratio of 50:50 WATER FOR MIXING Use distiled water only. Water other than distiled water can corrode and clog the aluminum radiator. ANTL-FREEZE & SUMMER COOLANT The coolant performs as corrosion and rust inhibitor as well as antifreeze. Therefore, the coolant should be used at all mes even though the atmospheric temperature in your area does not go down to freezing point. SUZUKI recommends the use of SUZUKI GOLDEN CRUISER 1200NA anti-freeze & summer coolant. If this is not available, use an equivalent which is compatible with aluminum radiator. '99000-99032-10X : SUZUKI GOLDEN CRUISER 1200NA (Non-Amine type) REQUIRED AMOUNT OF WATER/COOLANT Solution capacity (total) : 1 050 mi (0.9 Imp qt) CAUTION: Mixing of anti-freeze & summer coolant should be ing beyond it would reduce its efficiency. If the anti-freeze & summer coolant mixing ratio is below 30%, rust ing performance is greatly reduced. Be sure to mix it above 30% even though the atmospheric temperature does not go down to freezing point. BREAKING-IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard, but it is still necessary to allow the moving parts to “BREAK-IN" before subjecting the engine to maximum stresses. The future performance and reliablty of the engine depends on the care and restraint exercised during its early life. The general rules are as follows. © Keep to these breaking-in engine speed limits. Initial 800 _km (500 miles) Below 6 000 r/min Up to 1 600 km (1 000 miles) | Below 12000 r/min Over 1 600 km (1 000 miles) | Below 13000 r/min GENERAL INFORMATION 1-21-3 GENERAL INFORMATION SPECIAL MATERIALS ‘The materials listed below are needed for maintonace work on the AG 150 E/ES and should be kept on hand for ready use. They Supplement such standard materials as cleaning fds, lubrications, emery cloth and the tke. How fo use them and where to use them ‘10 described in the text of this manual 99000-32080 Material Part Page Part Page Throttle gp 22 | eWheot bearings 22 @Cutch lever 22 75 ‘© Speedometer cable 22 724 ‘© Speedometer goar box 22 | eFront fork ol seal m4 75 | @Stooring stem bearing m9 (© Brake pedal shatt 22 722 Side stand 22 | eSwingarm bearing and dust seal | 7-38 @Crankcase oi seal 27 7.33 Pepi ‘@.cushion lever and rod bearing 733 GREASE “Av a 98009-25010 ‘© Crankcase mating surface 33 ‘© Water thermogauge 410 (¢ Exhaust valve holder stud bolt 38 (¢ Seal coating pump 43 99000-31110 ‘@ Engine sprocket bot 35 ‘© Exhaust pulley bolt 35 ‘exhaust valve arm screw 38 ee) (@.2nd rive gear 336 = ‘© Serew for Transmission 332 and Gear 333 1322" 99000-90110 4 ‘© Gearshitt arm stopper 333 THREAD LOCK SUPER, 1303"GENERAL INFORMATION 1-4 Part Page Part Page (© Front fork 4 18 ‘SUZUKI FORK OIL #10 '99000-99044-106, © Dise batt, 75 724 ‘THREAD LOCK SUPER 1960" 99000-92020 © Caiiper ante 78 ( © Brake Front Rear m1 7:28 ‘SUZUKI SILICONE : GREASE 99000-25100 a (© Brakes Front Rear 1 A 2a ‘SUZUKI BRAKE FLUID ‘90000-23110 (0.6L) {© Cooling solution 42 ‘SUZUKI GOLDEN CRUISER 1200NA (Non-Amine type) 98000-99032-10X1-5 GENERAL INFORMATION PRECAUTIONS AND GENERAL INSTRUCTIONS Observe the following items without fail when disassembling and reassembling motocycles. (1 do not run engine indoors with litle or no ventilation (1 Be sure to replace packings, gaskets, citcips, O-rings and cotter pins with new ones. CAUTION: Never reuse a circlip after a circlip has been removed from a shaft, it should be discarded and a ew circlip must be installed. When installing a new circlip, care must be taken not to expand the end gap larger than required 1o slip the circlip over the shaft. After installing a circlip, always insure that is completely seated in its groove and securely fitted. (JJ Tighten cylinder head and case bolts and nut beginning with larger diameter and ending with smaller diameter, and from inside to outside diagonally, to the specified tightening torque. Use special tools where spicitied. Use genuine parts and recommended oils When more than 2 persons perform work together, pay attention to the safety of each other. Alter the reassembly, check parts for tightness and operation. Treat gasoline, which is extremely flammable and highly explosive, with greatest care, Never use gasoline as cleaning solvent Warning, Caution and Note are included in this manual occasionally, descr WARNING 19 the following contents. The personal safety of the rider or bystanders may be involved. Disregarding this information could result in personal injury. CAUTION .. These instructions point out special service procedures or precautions that must be followed to avoid damaging the machine. NOTE vo This provides special information to make maintenance easier or important instructions clearer. REPLACEMENT PARTS. When you replace any parts, use only genuine SUZUKI ———— replacement parts, or their equivalent. Genuine SUZUKI parts are high quaity parts which are designed and buit spectically for SUZUKI vehicles. CAUTION: Use of replacement parts which are not equivalent in quality to genuine SUZUKI parts can lead to performance problems % and damage5PECIFICATIONS NMENSIONS AND DRY MASS Drea lenge | Drea wth >roral hel reabase - Srv cearance Dive chain ciassis Front suspension eat suspension Steenng. ange Caster Tal Tuning acs Fron brake Paar brake Frente ze Pear tre size Frere for st Pear whee! wave ELECTRICAL Ignton he Ign tring Soar pig, Fase aig Taraks ight Tur sana ight Paston gh Tun signal indian‘ gh Beam indestr tht Ot evel indicator sont Newallegeator ght ‘Speedometer ght Tachometer ight Cala lmperaure cir ght caracmies Fel tank neusing reserve ever Engna ol tak Front fr of (each tog). Transmssion ol aan These specestons are subject to change wahout stce. GENERAL INFORMATION 1-6 1.996 se 18 ia3 cs 7 a 329223 Two-stroke atercooled Feed vane ; 1.00 mn 5380 mm se MIKUMI TH 20 TYPE SLINGSHOT rary ‘SUZUKI “cor Wit matipite ype ‘speed constant mesh ‘own, Sup 380 (6720) 2997 (47/6) 266 2a) ‘as? (aut) 1589 (20's) 095 (223) ate (zz) ss (aoe) DAIDO DLOIB VCA,TAKASAGO RI 420 HO, 130 tks Telescope col sping. ll dampe Swigam, cot spn ol damped 35r (gnt 8 et 2s St mm 26m Disc rake Bese rake sois0-7 95 4 PR 2o}0.17 61s 11000-17 605 4PR 130 0m 320 mm suzuxi ‘cor 14" BTDC at 1400 rm NGK'B BES, weaeSC 12V 108K (aan) OHA ia (oon0W (erayaw tow iow aw iw iw Ww rw aw wo aot 2 OU oem 108m 1080