MAY-24-2002 1! GPO 180302 CERTIFIED P2116, go OBE Reerz, Wot Regen, - ~ ‘pa’ Performance erformance Motorcycle Parts Motorcycle Parts 440-985-3853 440-985-3853 mar, Mhh OUT RACING Performance Motorcycle Parts *\, 440-985-3853 SUZUKI =F SOoo= SERVICE MANUAL ww Opt Reeg oy, Out Ree, & eect wae,” Performance erformance Motorcycle Parts Motorcycle Parts 440-985-3853 440-985-3853 Mh OUT FACING BRB performance Motorcycle Parts "ya 440-985-3853 : 99500-35034-03E SUZUKI MOTOR CORPORATION PRINTED IN JAPAN JULY, 93 @® AcMAY-24-2882 15:29 GPO 180302 CERTIFIED SUZUKI P2116, i | SERVICE MANUAL SUZUKI MOTOR CORPORATION PRINTED IN JAPAN JULY, '93 @ 99500-95034-03E ()MAY-24-2002 15129 FOREWORD This manual contains an introductory description on SUZUKI RF6OOR and procedures for its inspec- tion/service and overhaul of its main components. Other information considered as generally known is not included. Read GENERAL INFORMATION section to familiarize yourself with outline of the vehicle and MAINTENANCE and other sections to use as a guide for proper inspection and service. This menual will help you know the vehicle bet- ter $0 that you can assure your customers of your optimum and quick service. GPO 1809082 CERTIFIED P.e2/16 * This manual has been prepared on the basis of the latest specification at the time of publication. 1 moditication has been made since then, difference may exist between the content of this manual and the actual vehicle. ‘*Mustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual vehicle exactly in detail. * This msnual is intended for those who have enough knowledge and skills for servicing SUZUKI vehicles. Without such knowledge and skills, you should not at- tempt servicing by relying on this manual only. Instead, please contact your nearby au- thorized SUZUKI motorcycle dealer. IMPORTANT All street-iegal Suzuki motorcycles with engine displacement of 50cc or greater are subject to Environmental Protection agency emission regul- lations. These regulations set specific standards for exhaust emission output levels as well as par- ticular servicing requirements, This manual in- cludes specific information required to properly inspect and service RF6OOR in accordance with all EPA regulations. It is strongly recommended that the chapter on Emission Control, Periodic Servicing and Carburetion be thoroughly reviewed before any type of service work is per- formed. Further information concerning the EPA emission regulations and U.S, Suzuki's emission control progrem can be found in the U.S. SUZUKI EMIS- SION CONTROL PROGRAM MANUAL/SERVICE BULLETIN. SUZUKI MOTOR CORPORATION Motorcycle Service Department © COPYRIGHT SUZUKI MOTOR CORPORATION 1993MAY-24-2002 15129 GPO 1809082 CERTIFIED P.23/16MAY-24-2882 15:38 P4716, GENERAL INFORMATION CONTENTS SUZUKI RFGOORR (°94-MODEL) - SERIAL NUMBER LOCATION FUEL, Oil. AND ENGINE COOLANT RECOMMENDATIONS FUEL ~ ENGINE ONL - BRAKE FLUID -: FRONT FORK OIL ENGINE COOLANT WATER FOR MIXING ANTL-FREEZE/ENGINE COOLANT LIQUID AMOUNT OF WATER/ENGINE COOLANT BREAK-IN PROCEDURES - CYLINDER IDENTIFICATION - SPECIAL MATERIALS -- PRECAUTIONS AND GENERAL INSTRUCTIONS REPLACEMENT PARTS INFORMATION LABELS SPECIFICATIONS ~~ COUNTRY OR AREA - ®ONNAWENNNNNHNS SWSMAY-24-2002 15:38 GPO 1809082 CERTIFIED P.25/16 GENERAL INFORMATION SUZUKI RF6OORR (’94-MODEL) RIGHT SIDE LEFT SIDE ‘Difference between photographs and actual motorcycles depends on the markets. 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 right side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts. 7 we FUEL, OIL AND ENGINE COOLANT RECOMMENDATIONS. FUEL 1. Use only unleaded gasoline of at least 87 pump octane (24M) method or 91 octane or higher rated by the research method. . 2, Suzuki recommends that customers use alcohol free, unleaded gasoline whenever possible. 3. Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted, 4. Use of blended gasoline/alcoho! fuel is permitted provided that it contains not more than 10% ethanol. Gasoline/alcohol fuel may contain up to 5% methanol if appropriate cosolvents and cor. rosion inhibitors are present. 6. If the performance of the vehicle is unsatisfactory while using blended gasoline/alcohol fuel, you should switch to aleohol free unleaded gasoline. 6. Failure to follow these guideline could possibly void applicable warranty coverage. Check with you fuel supplier to be sure that the fuel you intend to use meets the requirements listed above.MAY-24-2002 15:38 GPO 1809082 CERTIFIED ENGINE OIL SUZUKI recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or an oil which is rated SE or SF under the API (American Petroleum Institute) classification system. The viscosity rating is SAE 10W/40, If an SAE 10W/40 mo- tor oil is not available, select an alternate according to the right chart. BRAKE FLUID Specification and classification: DOT4 WARNING: i * Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufac- turer, do not use or mix different types of fluid such as silicone-based and petroleum-based fi for refilling the system, otherwise serious damage will result. * Do not use any brake fluid taken from old or used or unsealed containers. * Never re-use brake fluid left over from a previous servicing, which has been stored for a long period. FRONT FORK OIL Use fork oi # 10 ENGINE COOLANT Use an anti-freeze/engit only. WATER FOR MIXING Use distilled water only, Water other than distilled water can corrode and clog the aluminum radiator. ANTI-FREEZE/ENGINE COOLANT The engine coolant perform as a corrosion and rust inhabit as well as anti-freeze. Therefore, the en- gine coolant should be used at all times even though the atmospheric temperature in your area does Rot go down to freezing poi LIQUID AMOUNT OF WATER/ENGINE COOLANT Solution capacity (total): 2460 ml (2.6/2.2 US/Imp qt) an aluminum radiator, mixed with distilled water coolant compatible For engine coolant mixture information, refer to cooling system section, page 5-4. CAUTION: Mixing of anti-freeze/engine coolant should be limited ‘to 60%. Mixing beyond it would reduce its efficiency, If the anti-fraaze/engine coolant mixing ratio is below 50%, rust inhabiting performance Is greatly reduced. Be sure to mix it above 50% even though the atmosphe ‘temperature does not go down to the freezing point.MAY-24-2082 15:31 GPO 180302 CERTIFIED : P2716, 1.3. GENERAL INFORMATION BREAK-IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished toa very high standard but it is still necessary to allow the moving parts to ““BREAK-IN” before sub- jecting the engine to maximum stresses. The future performance and reliability of the engine de- pends on the care and restraint exercised during its early life, The general rules are as follows. ‘* Keep to these break-in engine speed limits: Initial 800 km ( 500 miles): Below 7000 r/min Up to 1600 km (1000 miles): Below 10000 r/min Over 1600 km (1000 mites): Below 13500 r/min * Upon reaching an odometer reading of 1600 km (1000 miles} you can subject the motorcycle to full throttle operation. However, do not exceed 13500 r/min at any time, CYLINDER IDENTIFICATION The four cylinders of this engine are identified as No.1, No.2, No.3 and No.4 cylind. from left to right (as viewed by the fider on the seat). as countedMAY-24-2002 15#31 GPO 1809082 CERTIFIED P.28/16 DNERAL INFORMATION 1-4 —_———. SRL INFORMATION 1-4 SPECIAL MATERIALS ‘The materials listed below are needed for maintenance work on the RF6OOR, and should be kept ‘on hand for ready use. They supplement such standard materials as cleaning fluids, lubricants, emery cloth and the like. How to use them and where to use them are described in the text of this manual MATERIAL PART PAGE * Brake pedal pivot Be + Footrest pivot 22 * Gearshift lever pivot 22 ® Side-stand pivot and spring hook 22 * Driveshaft oll cea! 342 * Generator O-ring 387 * Starter motor O-ring 357 * Water pump O-ring 356 « Starter motor oil sea! 617 © Wheel bert 7-9, 44 * Speedometer gear box dust seal 740 * Steering stem bearing and dust sea! 7-32 ‘= Swingarm spacer, washer, bearing and dust seal | 7-51 ‘* Cushion leveritod bearing 7-82 ++ Water pump oil seat ‘ B13 '* Sprocket mounting drum bearing and of seal 7-45 ‘SUZUKI SUPER GREASE * Valve stem 3:26 * Conrod big end bearing 3:36 '* Countershatt and driveshaft 342 * Piston pin 358 '* Crankshaft journal bearing 3-49 ¢ Camshaft journal and cam face 3-60 «Starter metor armature end 617 _ ‘SUZUKI MOLY PASTE 98000-25140MAY-24-2002 15#31 1.5_GENERAL INFORMATION GPO 1809082 CERTIFIED P.29716 99000-32050 TERA 7 Fee] Oi pers ooh Sar TRE ease oper ant ower canteen | 255 sigan sce of upg on ig LE ae ne ng is 1 cee ont nd win cree 33 oe ice San sass er 33 echo oy ONT oe aa ¢ Water pump mechanical sea! S13 suzuei pon wo.12070 are Tai ear 7s 3 Gah Sear gis rew ond tok a sna 3 1S A Erbe 8 Tneno race suren “sea” pen Susie ame Fong Ton ou Rantio soari ak se Ce Ee a eee 38 1 SUR eh ast tn i Sent com bade sm Sau saree, an 2 ee row ‘y ee ig Lee er 333 1 Semen cam sor 3 + geuai cum ore 4% rane some or i3 SPOR Spr oa oa 3 Tinea Lock 1342"MAY-24-2002 15+ GPO 1809082 CERTIFIED P.10/16 GENERAL INFORMATION MATERIAL PART PAGE ‘Brake disc mounting bolt 79,47 THREAD LOCK SUPER "1360" 99000-32130 * Front fork 7-28MAY-24-2002 15:32 GPO 1809082 CERTIFIED P.11716 GENERAL INFORMATION PRECAUTIONS AND GENERAL INSTRUCTIONS Observe the following ms without fail when disassembling and reassembling motorcycles. T Do not run engine indoors with little or no ventilation, CBee sure to replace packing, geskets, circlips, O-rings and cotter pins with new ones. CAUTION: Never reuse a circilp, After a circlip has been removed from a shaft, It should be discarded and a Rew circlip must be installed. ‘When installing @ new circlip, care must be taken not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip. always insure that It is complotoly seated in Its groove and securely fitted. Oi Tighten cylinder head and case bolts and nuts beginning with larger diameter and engine with ‘smaller diameter, and from inside to out-side diagonally, to the specified tightening torqu O Use special tools where specified. Cl Use genuine parts and recommendad oils. 1D When 2 or more persons work together, pay attention to safety of each other. CO Atter 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, describing the following contents. WARNING + The personal safety of the rider may be involved. Disragarding this infor- mation could result in injury to the rider. CAUTION .. +++ These instructions point out special service procedures or precautions that must be followed to avoid damaging the machine. NOTE .. . This provides special information to make maintenance easier or impor- tant instructions clearer. REPLACEMENT PARTS When you replace any parts, use only genuine SUZUKI replacement parts, or their equivalent. Genuine SUZUK( parts. are high quality parts which are designed and built specifi- cally for SUZUKI vehicles. CAUTION: Use of replacement parts which are not equivalent in quali- ty to genuine SUZUKI parts can lead to performance problems and damage.MAY-24-2002 15:32 GPO 1809082 CERTIFIED P.12/16 GENERAL INFORMATION 1-8 INFORMATION LABELS 1D plete (Except for U.S.A. and CANADA models) Safety (al For U. Noise label | (For £-21, E24 modele) ‘AOmm y} National safety fabet (Only for CANADA mod a ” RH VIEW Soreen warming label (Only for CANADA model) Screen warning abot (For U.S.A. and CANADA modeta) Right-side of cowllng upper pane!MAY-24-2002 15:32 GPO 1809082 CERTIFIED P.1316 1-9 GENERAL INFORMATION Warning safety label (For -02, €-24 models) Vacuum hose routing diagram (Only for Calit. model) Fuel caution information Fadl aie (For E-02, E-24 models) jarring safety label (Except for £-02, £-24 models}MAY-24-2882 15:33 GPO 180302 CERTIFIED P.14716, GENERAL INFORMATION 1-10 i EMERAL INFORMATION 1-10 SPECIFICATIONS DIMENSIONS AND DRY MASS. Overall tength sss Overall width Overall height Wheelbase .. + 2.110 mm (83.1 in) 710 mm (28.0 in} 1.175 mm (46.3 in) 1 430 mm (56.3 in) Ground clearance ... 120 mm (4.7 in} Dry mass. 195 kg (429 Ibs) ... For E-03 model 198 kg (436 Ibs) ... For E-33 model ENGINE Type Four-stroke, Water-cooled, DOHC, TSCC. 4 65.0 mm (2.589 in) Number of cylinders Bore . Stroke .. 45.2 mm (1.780 in) Piston displacement 599 cm? (36.5 cu. in} Carburetor .. MIKUNI BDSTS3S ..... For E-33 model MIKUNI BDST36 ..... For E-03 model Non-woven fabric element Electric starter Lubrication system .. Wet sump ane TRANSMISSION Clutch .. . Wet multi-plate type Transmission 6-speed constant mesh : 1-down, 5-up Primary reduction rati 1.744 (78/43) Final reduction ratio ... + 3.071 (43/14) Gear ratios, Low . 2nd 3rd ath Bth ... Top 3.142 (44/14) srsseee 2,058 (35/17) - 1,650 (33/20) - 1.428 (30/21) - 1.260 (29/23) - 1.120 (28/25) . RK50GSVZ1, 108 links or DID SOVA7, 108 links Drive chainMAY-24-2002 15:33 GPO 1809082 CERTIFIED P.15/16 1,11. GENERAL INFORMATION. CHASSIS Front suspension .. . Telescopic, coil spring, oil damped, spring pre-load adjustable. . Link type system, oil damped, coil spring, spring pre- load adjustable and rebound damping force ad- justable. Steering angle - 30° (right & left) Caster ... . 65° Treil i - 103 mm (4.1 in) Turning radius . 3.2 m (10.5 ft) Front brake . Disc brake, twin Rear brake Disc brake Front tire S128 ssscesense . 120/70 2R17, tubeless Rear tire size . 160/60 2R17, tubsless Front fork stroke 120 mm (4.7 in) Rear wheel travel. 130 mm (5.1 in) Rear suspension ... ELECTRICAL Ig Electronic Ignition (Fully Transistorized) Ignition timing a 4° BILD. at 1500 r/min ..... For E-33 mode! 7° BT.DC. at 1500 r/min ..... For E-O3 model NG. ‘Spark plug ROE, NIPPONDENSO U27ESR-N Battery 12V 28.8 KC (8 Ah)/10 HR Generator .. Three-phase A.C. Generator Main fuse . res 30A . Fuse .. 18/15/15/10/10A Headlight 12V 6o/s5W Turn signal light 12v 21W Taillight .. 12V sw Brake light 12V 21W x2 License piate light 12V SW 12V 1.7Wx2 12V 1.7Wx 2 12V 1.7W 12V 3.4W 12V 3.4W 12V 3.4w 12V 3.4W Tachometer light Engine coolant temp. meter light Neutral High beam indicator light Turn signal indicator light .. Oil pressure indicator light .. CAPACITIES Fuel tank, including reserve .... 17.0 L (4.5/3.7 US/Imp gal) ... For E-03 model 16.0 L (4.2/3.5 US/Imp gal) ... For E-33 model Engine oil, oil change 3 000 mi (3.2/2.6 US/Imp qt) with filter chang 3 300 mi (3.5/2.9 US/Imp qt) overhaul .. 3 900 mi (4.1/3.4 US/Imp qt) Front fork oil ... 503 mi (17.0/17.7 US/imp oz) Coolant . sseseeee 2 450 mil (2.6/2.2 US/Imp at) These specifications are subject to change without notice.MAY-24-2002 15:33 COUNTRY OR AREA GPO 1809082 CERTIFIED P.16/16 GENERAL IWURMIALIUN 1-12 ‘The series of symbols on the left stand for the countries or area on the right. ‘SYMBOL COUNTRY or AREA £02 £03 £33 E04 E15 E16 E17 E18 £21 E22 E24 E25 £28 E34 E53 England U.S.A. California (U.S.A.) France Finland Norway ‘Sweden Switzerland Belgium Germany Australia Netherlands Canada Italy Spain TOTAL P.16MAY-24-2882 15:35 GPO 180302 CERTIFIED P.e1724 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES LUBRICATION POINTS © EXHAUST PIPE BOLTS « AIR CLEANER «-- TAPPET CLEARANCE SPARK PLUG - FUEL LINE FUEL FILTER ~ CARBURETOR CLUTCH DRIVE CHAIN COOLING SYSTEM - BRAKE © TIRE -- STEERING : FRONT FORK REAR SUSPENSION OIL PRESSURE CHECK PERIODIC MAINTENANCE SCHEDULE PERIODIC MAINTENANCE CHART MAINTENANCE AND TUNE-UP PROCEDURES ENGINE OIL AND OIL FILTER - CHASSIS BOLTS AND NUTS -- COMPRESSION PRESSURE CHECK CONTENTS- SRA HEN AHMAY-24-2002 15136. GPO 1809082 CERTIFIED P.e2v24 2:1_PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES: PERIODIC MAINTENANCE SCHEDULE IMPORTANT: The periodic maintenance intervals and service requirements have been established in accordance with EPA regulations. Following these instructions will ensure that the motorcycle will not exceed emission standards and it will also ensure the reliability and performance of the motorcycle. ‘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. Mileages are expressed in terms of Kilometer, miles and time for your convenience. NOTE: ‘More frequent servicing may be performed on motorcycles that are used under severe conditions however, it is not necessary for ensuring emission level compliance. PERIODIC MAINTENANCE CHART Interval [km 7000 | 6000 | 12000 | 18000 | 24000. ‘miles | 600 | 4000 | 7500 | 11000 | 15000 Item months | 2 32 24 36 48 Exhaust pipe bolts = T T T T Air cleaner = o D Rg 0 Tappet clearance = = 1 = 1 Spark plug = 1 R C R Engine oll R R R R R Engine oil filter R = R = R Fuel fine = o i i i (EVAP hose......-. California model only) Heplace every 4 veare Fuel fitter = = c = Cc Engine idle rpm (Carburetor) 1 o 1 1 0 Throttle cable play (Carburetor) i 0 i H 1 Clutch cable play = i H i i 0 0 1 1 i Brive chain Lubricate every 1000 km (600 miles) = 7 t o t Replace every 4 years Radiator hose Engine coolant Replace every 2 years Brake 0 H H 1 H = 1 i 0 H Brake hose Replace every 4 years Brake fluid _ 4 1 ! 1 Replace every 2 years Tire = 1 r 1 Steering 1 = 1 Front fork = = 0 Rear suspension 7 = 1 ‘Chassis boits and nuts T T T T 1= Inspection end adjust, clean, lubricate or replace as necessary C=Clean R= Replace T= Tighten ' a]-}-|-|-MAY-24-2002 15136. GPO 1809082 CERTIFIED P.e3724 LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrici jon points are indicated below. oi Grease B Gearshift lever pivot ciutch lever holder and footrest pivot ‘and clutch cable Brake pedal pivot Bora oowen pect IH Sidestond pivot NOTE: * Before lubricating each part, clean off any rusty spots and wipe off any grease, all, dirt or grime. * Lubricate exposed parts which are subject to rust, with # rust preventative spray whenever the motorcycle has been operated under wet or rainy conditions,MAY-24-2882 15:36 GPO 180302 CERTIFIED PERIODIC MAINTENANCE AND TUNE.UP PROCEDURES MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements. EXHAUST PIPE BOLTS Tighten Every 6000 km 100 ‘* Remove the lower cowling assembly. (Refer to page 7-2.) ‘* Remove the radiator mounting bolts. (Refer to page 3-4.) * Tighten the exhaust pipe clamp bolts and muffler mount- ing bolts to the specified torque with a torque wrench. Exhaust pipe clamp bolt 18-28 Nm & Muffler mounting bolt _: (1.82.8 kg-m, 13.0—20.0 Ib-ft) 4 AIR CLEANER Inspect Every 6000 km (4000 miles, 12 months) and Replace Every 18000 km (11000 miles, 36 months). + Remnve the seats, frame cover assembly and fuel tank. (Refer to pages 7-5 and 4-5.) ‘+ Remove the air cleaner element by removing the screws ‘* Carefully use air hose to blow the dust from the cleaner element. CAUTION: Always use air pressure on the inside of the air cleaner el ment. If ait pressure is used on the outside, dirt will be forced into the pores of the air cleaner element thus 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 in the cleaner case, make sure that the $ mark @comes upward. CAUTION: if driving under dusty condition, clean the air cleaner ele- ‘ment more frequently. The surest way to accelerate engine wear is to use the engine without the element or to use a ruptured element. Make sure that the air cleaner is in good condition at all times. Life of the engine depends largely on this component! NOTE: When you clean the air cleaner element, drain water from the air cleaner drain hose by removing the drain plug. P8424MAY-24-2002 15137 GPO 1809082 CERTIFIED P.eS5724 ERIODIC MAINTENANCE AND TUNE.UP PROCEDURES 24 TAPPET CLEARANCE Inspect Every 12000 km (7500 miles, 24 months). * Remove the seats, frame cover assembly, lower cowling assembly and fuel tank. (Refer to pages 7-2, 7-6 and 4-5.) ‘= Remove the air cleaner box and carburetors. (Refer to pages 3-2 and 3.) ‘+ Remove all the spark plugs. ‘* Remove the cylinder head cover. (Refer to page 3-10.) ‘The tappet clearance specification is different for both take and exhaust valves. Tappet clearance adjustment must be checked and adjust- ed, 1) at the time of periodic inspection, 2) when the valve mechanism is serviced, and 3) when the camshafts are dis- ‘turbed by removing them for servicing. Topper clearance {when cold): IN. : 0.10—0.20 mm (0.004— EX.: 0,200.30 mm (0,008— NOTE: * The cam must be at positions, Bar ®, in order to check the tappet clearance, or to adjust teppet clearance. Clear- ance readings should not be taken with the cam in any ‘other position than these two positions, * The clearance specification is for COLD state. * To turn the crankshaft for clearance checking, be sure to use @ 19-mm wrench, and rotate in the normel running direction. All spark plugs should be removed. 008 in) .012 in) * Turn crankshaft to bring the “"T’” mark on the rotor to the center of pick-up coil and also to bring the notches @ i the right ends of both camshafts (Ex and In) to the posi- tions shown. In this condition, read the tappet clearance at the valves ©(In and Ex of No.1 cylinder, Ex of No.2 and In of No.3). * Use a thickness gauge between the tappet and the cam. If the clearance is out of specification, bring it into the specified range. 09900-20803: ThiMAY-24-2002 15137 GPO 1809082 CERTIFIED 2.5 PERIODIC MAINTENANCE AND TUNEUP PROCEDURES P2624 © Turn the crankshaft 360° (one rotation) to bring the “T’” mark on the rotor to the center of pick-up coil and also to bring the notches @ to the positions shown. ‘* Read the clearance at the remaining valves Qand adjust the clearance if necessary. Notch @ position Gam Position |Treake Camshaft _| Exhaust Camshaft © S @ ® S © TAPPET CLEARANCE ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim by a thicker or thinner shim. ‘« Remove the intake or exhaust camshafts. (Refer to page 3-44) ‘* Remove the tappet and shim by fingers or magnetic hand. (Refer to page 3-21.) © Cheok the figures printed on the shim. These figures in- dicate the thickness of the shim, as illustrated, + Select @ replacement shim that will provide a clearance within the specified range. For the purpose of this adjust- ment, a total of 21 sizes of tappet shim are available rang- ing from 1.20 to 2.20 mm in steps of 0.05 mm. Fit the selected shim to the valve stem end, with numbers toward ‘tappet. Be sure to check shim size with micrometer to en- sure its size. Refer to the tappet shim selection table for details. NOTE: * Be sure to apply engine oil to tappet shim top and bot- tom faces. * When seating the tappet shim, be sure to face figure print- ed surface to the tappet. « After replacing the tappet shim and camshafts, rotate the engine so that the tappet is depressed fully. This will ‘squeeze out oil trapped between the shim and the tappet that could cause an incorrect measurement, then check the clearance again to confirm that it is within the speci- fied range. ‘* When installing the cylinder head cover, apply SUZUKI BOND NO. 12078 to the head cover groove and cam end caps, (Refer to page 3-64.) © Tighten the head cover bolts to the specified torque. (Refer to page 3-65.) 1,70 mm ShimP.ar24 GPO 1809082 CERTIFIED 15:38 MAY-24-2002 (INTAKE SIDE) pruozpoyy ors unis 109 St SNOW, 2ouswa[a Ledder eiesory *) aus QB’ pa8n 29 or exe UES ‘uw og"1 ore wan woes wu ez'0 sy eounseap auasvxa es ore [we oe oz, eee [ave mz for [are [ove | soz [aoe “s4NVHO SIML 387 OL MOH oz [siz | ore aoe ez [are [ove [502 [ove fore [wz [ore [soz | o0z [oer on Ti ore. oan [aes 090-850 ‘ove [ave sc [oct | son won forz [ave fore ol ‘50-9 wz [arz | ove [oor ae sro-1wo ore [sre [ore | soz [oor oF ov0-se0 (oz [rz [ove [soz [ooz [aor om se0-1Fo vez [sre fore [soz | oo | 26% [0 os or oz Joce sve ore [soz [coz | se ov [see ‘Gaia INBWISHTOY OMONVEVITO GalsIOadS. [sr Jove [soz [oor [seu [05s [ves Joos [are fort ox [ori [ors [see fore [soe [ove [se |ors | ons foat far foci too srs fort [oes ore [ace ove |av2| ove ]soz | ooz | so 05's} sor | o ox | siz | ove | soe | ove | st | ost [i0z8S0-00871) “ON 135 WIHS 13dd¥iL {x & X-00990°768Z1)'ON WHS LaddV1. [VNU] J18V1 NOILI3IT3S WIHS 13ddVLP.eB724 GPO 1809082 CERTIFIED RIDDIC MAINTENANCE AND TUNE.UP PROCEDURES MAY-24-2002 15:38 (EXHAUST SIDE) uu oar pasn oq or ozs wang, au e's Bae WINE EON wu ge'9 my aouersep vedee, Stans | "uamoo wonsoy uy 22s ways woseid quia uno RIAA wy GoUEIEOP YEA, 1109 SI 3MIDNB,,"=5UEME vedo! assy “| HLUVHO SIL 38n OL MOR aro-sro pro-ore {X x X-009S0°26B7L)'ON WIHS Laddv (02880-00821) “ON 13S WIHS Laddv1 [LSAVHXAl 318VL NOLLOFTSS WIHS Laddv1 90-590MAY-24-2002 15:38 GPO 1809082 CERTIFIED SPARK PLUG Inspect at 6000 km {4000 miles, 12 months), 18000 km (11000 miles. 36 months) and Replace Every 12000 km (7500 miles, 24 months). * Remove the seats, frame cover assembly and fuel tank. (Refer to pages 7-5 and 45.) © Remove all the spark plugs. NOTE: if it is difficult to remove the spark plug cap, pry up it with a screwdriver, (09930-10121: Spark plug socket wrench set 09930-14530: Universal joint 09914-24510: T handle 09900-20803: Thickness gauge (= [standard] Cold type | Hot type NGK CROE CRIOE CRE ND U27ESR-N | U31ESR-N | U24ESR-N CARBON DEPOSIT Check to ses the carbon deposit on the plug. If the carbon is deposited, remove it with @ spark plug cleaner machine or carefully using @ tool with a pointed end. SPARK PLUG GAP Measure the plug gap with a thicknass gauge Mf not, adjust it to the following gap. itis correct. ‘Standard 0.70.8 mm (0.028—~0.032 in) ‘Spark plug gap 09900-20803: Thickness gauge ELECTRODE’S CONDITION Check to see the worn or burnt condition of the electrodes. If it is extremely worn or burnt, replace the plug. And also replace the plug if it has a broken insulator, damaged thread, ete. CAUTION: Confirm the thread size and reach when replacing the plug. If the reach is too short. carbon will be deposited on the screw portion of the plug hole and engine damage may result. P.09724 7ERIODIC MAINTENANCE AND TUNEUP PROCEDURES 2.8MAY-24-2002 15:39 GPO 1S09@82 CERTIFIED pic MAINTENANCE AND TI »ROCEDURES. ENGINE OIL AND OIL FILTER (ENGINE OIL) Replace initially at 1000 km (600 miles, 2 months) and Every 6000 km (4000 miles, 12 months) thereafter. OIL FILTER Replace Initially at 1000 km (600 miles, 2 months) and Every 12000 km (7500 miles, 24 months) thereafte Oil should be changed while the engine is warm. Oit filter replacement at the above intervals, should be done together with the engine oil changi + Keep the motoroyale upright. * Place an oil pan below the engine, and drain the oll by removing the drain plug @ and filler cap @ . + Remove the oil filter @ by using the oil filter wrench. {Special tool @) * Apply engine oil ightly to the gasket of the new filter be- fore installation. * Install the new filter turing it by hand until you feel that the filter gasket contacts the mounting surface. Then tight- en it 2 turns using the oil filter wrench, (Special tool @) 09915-40610: Oil filter wrench NOTE: To properly tighten the filter, use the special tool. Never tighten the filter by hand. * Fit the drain plug @ securely, and pour fresh oil through the ail filler. The engine will hold about 3.3 L (3.5 US gt} of oil. Use an API classification of SE or SF oil with SAE 1OW/40 viscosity. ‘* Start up the engine and allow it to run for several seconds 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 mark “F", add oil to that level. NECESSARY AMOUNT OF ENGINE OIL Oil change: 3.0 L (3.2/2.6 US/Iimp at) Filter change: 3.3 L {3.5/2.9 US/Imp qt) Overhaul engine: 3.9 L (4.1/3.4 US/imp qt) CAUTION: Use SUZUKI MOTORCYCLE GENUINE OIL FILTER only. since the ather make’s genuine filters and after-market parts may differ in thread specifications (thread diameter and pitch), filtering performance and durability, which could cause engine damage or oil leaks. Suzuki automobile genuine olf filter is also not usable for the motorcycles. P.10/724 ‘fiter After contacting the gasket, tightea 2 turns.GPO 1S09@@2 CERTIFIED P.11724 PERIODIG MAINTENANCE AND TUNE-UP PROCEDURES 2-10 FUEL LINE (EVAP HOSE ... California model only) Inspect Every 6000 km (4000 miles, 12 months). Replace Every 4 years. FUEL FILTER Clean Every 12000 km (7600 miles, 24 months). (Refer to page 4-5.) CARBURETOR IDLE RPM (idling adjustment) Inspect Initially at 1000 km (600 miles, 2 months) and Every 6000 km (4000 miles, 12 months) thereafter. NOTE: Make this adjustment when the engine is hot. * Connect a tachometer. ‘* Start up the engine and set its speed at anywhere between 1200 and 1400 r/min by turning throttle stop screw @ . Engine idle speed: 1300+ 100 r/min 1350+ 100 r/min £03 £33 THROTTLE CABLE PLAY Pulling cable play @ There should be 0.5—1.0 mm (0,02--0,04 in) play @in the throttle cable. Adjust the throttle cable play with the fol lowing procedures. * 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. Returning cable play © * Adjust the returning cable to the specified play in the same manner as the pulling cable play adjustment. Throttle cable play (@and ©): 0.5—-1.0 mm (0.02—0.04 in) WARNING: After the adjustment is completed, check that handiebar ‘movement does not raise the engine Idle speed and that the throttle grip returns smoothly and automatically.MAY-24-2002 15140 GPO 1809082 CERTIFIED 211 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES. CLUTCH Inspect Every 6000 km (4000 miles, 12 months). Remove the lower cowling assembly. * Loosen the cable adjuster lock nut @ and screw in the cable adjuster @ . + Loosen tha cable adjuster lock nut @ and screw in the cable adjuster @ to provide a play in the cable. * Adjust the clutch fever play with the cable adjuster @) until play of the clutch lever is within the following value. Clutch lever play @ — | 10-15 mm (0.4—-0.6 in) * If the specified play can not be obtained with the cable adjuster @ , carry out the adjustment with the cable ad- juster @ on the clutch lever side. * After adjusting the play, tighten the both cable adjuster lock nuts, © and @. DRIVE CHAIN Inspect initially at 1000 km (600 miles, 2 months) and Every 6000 km (4000 miles, 12 months) thereafter, Lubricate Every 1000 km (600 miles). Visually check the drive chain for the possible defects list- ed below. (Support the motoreycle by a jack and a wooden block, turn the rear wheel slowly by hand with the trans- mission shifted to Neutral.) * Loose pins + Excessive wear * Damaged rollers * Improper chain adjust- * Dry oF rusted links ment * Kinked or binding links * Missing O-ring seals, If any defects are found, the drive chain must be replaced. NOTE: When replacing the drive chain, replace the drive chain and sprockets as a set. P.12724MAY-24-2002 15140 GPO 1809082 CERTIFIED P.13724 PERIODIC MAINTENANCE AN TUNE.UP PROCEDURES 2.12 CHECKING ‘+ Remove the axle cotter pin. (For E-03, 28 and 33 models) * Loosen the axle nut @. © Tense the drive chain fully by turning both chain adjusters @. © Count out 21 pins (20 pitches) on the chain and meas- ure the distance between the two points. If the distance exceeds the service limit, the chain must be replaced. Service Limit 319.4 mm (12.6 in) Drive chain 20-pitch length ADJUSTING © Loosen or tighten both chain adjusters @ until the chain has 30—40 mm (1.2—1.6 in) of slack in the middle be- sprockets, The mark @ on both chain adjusters must be at the same position on the scale to ensure that the front and rear wheels are correctly ined, je-stand for accurate ad- justment. = After adjusting the drive chain, tighten the axle nut @ se- curely. ighten both chain adjusters @ securely. Rear axle nut: 85—115 N-m (8.5—11.5 kg-m, 61.5—83.0 lb-ft) CLEANING AND LUBRICATING * Wash the chain with kerosene. If the chain tends to rust quickly, the intervals must be shortened, CAUTION: Do not use trichlene, gasoline or any similar fluids: These fluids have too great a dissolving power for this chain and, what is more important, they can damage the “"0"’-tings (or seals) confining the grease in the bush to pin clearance. Remember, high durability comes from the presence of grease in that clearance. = After washing and drying the chain, oil it with a heavy- weight motor oil. CAUTION: * Donot usa any oil sold commercially as “drive chain oil”. ‘Such oil can damage the ““O’’-rings (or seals). * The standard drive chain TAKASAGO RKSOGSVZ1 or DAIDO DID5OVA7. ‘SUZUKI recommends that this standard drive chain should i be used for the replacement.MAY-24-2002 15140 GPO 1809082 CERTIFIED 2.13 PERIODIG MAINTENANCE AND TUNEUP PROCEDURES: P.14724 COOLING SYSTEM Inspect Every 6000 km (4000 miles, 12 months). Replace engine coolant Every 2 years. Replace radiator hoses Every 4 years. ENGINE COOLANT LEVEL ‘* Keep the motorcycle upright. * Chack the engine coolant level by observing the upper and lower limit lines on the engine coolant reservoir. «If the level is below the lawer limit line, add engine coolant to the upper limit line from the engine coolant reservoir filler. ENGINE COOLANT CHANGE * Remove the seats, frame cover assembly, lower cowling sembly and right side of cowling upper panel. (Refer to pages 7-2 and 5.) * Remove the radiator cap @ and disconnect the water hose ®, and drain engine coolant. WARNING: * Do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor. * Engine coolant may be harmful if swallowed or if it comes in contact with skin or eyes. If engine coolant gets into the ayes or in contact with the skin, flush thoroughly with plenty of water. If swallowed, induce vomitting and call physician immediately! ‘* Flush the radiator with fresh water if necessary. * Connect the water hose @ securely. '* Pour the specified engine coolant up to the radiator inlet. NO} For engine coolant information, refer to page 5-4. * Close the radiator cap @ securely. ‘© After warming up and cooling down the engine, add the specified engine coolant up to the engine coolant reservoir. CAUTION: Repeat above procedure several times and make sure that ‘the radiator is filled with engine coolant up to the engine coolant reservoir. Engine coolant capacity: 2450 ml (2.6/2.2 US/Imp qt)MAY-24-2002 15:41 GPO 1809082 CERTIFIED P.15724 PERIODIC MAINTENANCE AND TUNEUP PROCEDURES 2.14 BRAKE . > (BRAKE) Inspect Initially at 1000 km (G00 miles, 2 months) and Every 6000 km (4000 miles, 12 months) thereafter. (BRAKE HOSE AND BRAKE FLUID) Inspect Every 6000 km (4000 miles, 12 months). Replace hoses 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 lines on the front and rear brake fluid reservoirs. '» When the level is below the lower limit lina, replenish with brake fluid that meets the following specifi Specific ‘and Classification: DOT4 WARNING: ‘The brake system of this motorcycle is filled with a glycol- based brake fluid. Do not use or mix differant types of fluid ‘such as silicone-based or petroleum-based. Do not use any brake fluid taken from old, used or unsealed containers. Never re-use brake fluid laft over from the last servicing or stored for a long period, WARNING: Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces. Check the brake hoses and hose joints for cracks and oil leakage before riding. BRAKE PADS ‘The extent of brake pad weer can be checked by observing the grooved limit line © on the pad, When the weer exceeds the grooved limit ine, replace the pads with new ones. (Refer to pages 7-17 and 7-35.) CAUTION: Replace the brake pad as a set, otherwise braking perfor- mance will be adversely affected. ,MAY-24-2002 15:41 GPO 1809082 CERTIFIED P.16724 245 PERIODIC MAINTENANCE AND TUNEUP PROCEDURES: BRAKE PEDAL HEIGHT * Loosen the lack nut @ and rotate the push rod @ to lo- cate brake pedal 50—60 mm (2,0—2.4 in) @below the top face of the footrest. ‘+ Retighten the lock nut @ to secure the push rod @)in the proper position. Brake pedal height ©): 50—60 mm (2.0—2.4 in) 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, AIR BLEEDING THE BRAKE FLUID CIRCUIT Air trapped in the fluid circuit acts like a cushion to absorb ‘a large proportion of the prossure developed by the master i cylinder and thus interferes with the full braking performance of the brake caliper. The presence of air is indicated by “'sponginess” of the brake lever and also by lack of brak- ing force. Considering the danger to which such trapped ai exposes the machine and rider sential that, after mounting the brake and restoring the brake system to the normal condition, the brake fluid circuit be purged of air in the following manner:MAY-24-2002 15:41 GPO 1809082 CERTIFIED ‘ Fill up the master cylinder reservoir to the “UPPER” line. Replace the reservoir cap to prevent entry of dirt. * Attach a pipe to the caliper bleeder valve, and insert the free end of the pipe into a receptacle. Bleeder valve tightening torque: 6—9 N-m (0,6—0.9 kg-m, 4.5—6.5 Ib-ft) * Front brake: Bleed the air from the air bleeder valve. ‘© Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it. Loosen the bleader valve by turning it a quarter of @ turn so that the brake fluid runs into the receptacle; this will remove the tension of the brake lever causing it to touch the handlebar grip. Then, close the vaive, pump and ‘squeeze the lever, and open the valve. Repeat this process Until the fluid flowing into the receptacle no longer con- tains air bubbies. NOTE: Replenish the brake fluid in the reservoir as necessary while bleeding the brake system. Make sure that there is always some fluid visible in the reservoir, '* Close the bleeder valve, and disconnect the pipe. Fill the reservoir to the “UPPER” line. CAUTION: Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials otc. ‘+ The only difference between bleeding the front and rear brakes is that the rear master cylinder is actusted by a pedal. TIRE Inspect Every 6000 km (4000 miles, 12 months). UODIC MAINTENANCE AND TUNE-UIMAY-24-2002 15:42 GPO 1809082 CERTIFIED 2:17__PERIODIG MAINTENANCE AND TUNEUP PROCEDURES, 2:17_PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES TIRE TREAD CONDITION Operating the motorcycle with excessively wom 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 following specification. Tire tread depth limit: FRONT 1.6 mm (0.06 in) REAR 2.0 mm (0.08 in) in the correct tire pressure for good roadability or shorter tire life will result. Cold inflation tire pressure is as foltows. COLD INFLATION | _ SOLO RIDING’ DUAL RIDING TIRE PRESSURE [KPa |kgiom?|_psi_| kPa |kgiew™]_psi FRONT 225 |2.25| 33 | 260 [2.50/36 REAR, 250 |2.50[ 36 | 290 | 2.90] 42 CAUTION: ‘The standard tire fitted on this motorcycle is 120/70 ZR17 for front (DUNLOP D202F) and 160/60 ZR17 for rear {DUNLOP D202). The use of tires other than those speci- fied may cause instability. It Is highly recommended to use a SUZUKI Genuine Tire. STEERING Inspect Initially at 1000 km {600 miles, 2 months) and Every 12000 km (7500 miles, 24 months) thereafter. Taper roller type bearings are used on the steering system for better handling. Steering should be adjusted properly for smooth turning of handlebars and safe running. Overtight steering prevents smooth tuming of the handlebars and too loose steering will cause poor stability, Check that there is 1no play in the front fork assembly by supporting the machine 0 that the front wheel is off the ground, with the wheel straight ahead, grasp the lower fork tubes near the axle and pull forward. If play is found, perform steering bearing ad- justment as described in page 7-33 of this manual.MAY-24-2002 15:42 GPO 1809082 CERTIFIED WODIC_ MAINTENANCE AND Tl P.19724 ROCEDURES 2.18 FRONT FORK Inspect Every 12000 km (7500 miles, 24 months). Inspect the front forks for oil leakage, scoring or scratches ‘on the outer aurface of the inner tubes, Replace any defec- tive parts, if necessary. (Refer to page 7-24.) REAR SUSPENSION Inspect Every 12000 km (7500 miles, 24 months). Inspect the rear shock absorber for oil leakage and check that there is no play in the swingarm assembly.MAY-24-2002 15:42 GPO 1809082 CERTIFIED P2024 RIOGDIC_ MAINTENANCE AND Tt PROCEDURES, eee eee Oe eee eR NS CHASSIS BOLTS AND NUTS Tighten Initially at 1000 km (600 miles, 2 months) and Every 6000 km (4000 miles, 12 months) thereafter. ‘The nuts and bolts listed below are important safety related parts. They must be retightened when necessary to the specified torque with a torque wrench. (Refer to page 2-20 for the locations of the following nuts and bolts on the motoreyele.) item’ Nm Ibe @ Steering stem head nut ‘80-100 58.0-—72.5 @ Front fork upper clamp bolt 18-28 13,0—20.0 @ Front fork lower clamp bott 18—28 13.0—20.0 @ Front fork cap bolt ‘30-40 21,5—29.0 © Front axle 50-80 36,0—58.0 © Front axle pinch bolt 18-28 13.0—20.0 @ Handlebar holder mounting bolt and nut 22-35 16.0-25.5 @ Handlebar set bolt 18~-28 13.0—20.0 @ Front brake master cylinder mounting bolt 8-12 6.0—8.5, @ Front brake caliper mounting bolt 20-30 14.5-21.5 Ol ecie conan: 18-20 11.0-14.5 @ Air bieeder valve (Front & Rear) 6-9 45-65 @ Front and rear disc bolt 18—28 13.0—20.0 @ Front footrest bracket mounting bolt 18—28 13,0—20.0 ® Swingarm pivot nut 85118 61.5—83.0 @ Front footrest nut 42-66 30.5—47.5 @ pees eae mounting nut 40-60 29.0—43.5 @ Rear cushion leverirod mounting nut 70-100 7.0-10.0 | 50.5—72.5 ‘© Rear brake caliper mounting bolt 20-30 20-30 | 145-215 @ Rear brake caliper housing bolt 30-36 3.0-3.6 | 21.5260 @ Rear brake master cylinder mounting bolt 18—28 18-28 | 13.0—20.0 @ Rear axle nut 85-115 8.5-11.5 | 61.5-83.0 @ Rear sprocket nut 48-72 4.8-7.2 | 36.0-62.0MAY-24-2002 15:43 GPO 1809082 CERTIFIED P.2iv24 PERIODIC MAINTENANCE AND TUNEAUP PROCEDURES 2.20MAY-24-2002 15:43 GPO 1809082 CERTIFIED P.22724 2.21 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2:21_FERIODIC MAINTENANCE AND TUNE-UP PROCEDURES COMPRESSION PRESSURE CHECK The compression of a cylinder is a good indicator of its internal condition. ‘The decision to overhaul the cylinder is often based on the results of @ compression test. Periodic maintenance records kept at your dealership should include compression readings for each main- tenance service. COMPRESSION PRESSURE SPECIFICATION ¢ Standard | Limit, Difference 1000—1500. kPa ‘800 kPa 200 kPa (1018 kale) @kgler") 142-213 psi 28 psi Low compression pressure can Indicate any of the following conditions: * Excessively worn cylinder wall * Worn-down piston or piston rings * Piston rings stuck in grooves * Poor seating of valves + Ruptured or otherwi Overhaul the engine In the following cases: * Compression pressure in one of the cylinders is less than 800 kPa (8 kg/cm?, 114 psi). * Difference in compression pressure batween any two cylinders is more than 200 kPa (2 kg/em?, 28 psi). ee * All compression pressure are below 1000 kPa (10 kg/em?, 142 psi) even when they meaaure more ¢ than 800 kPa (8 kg/em?, 114 psi). defective cylinder head gasket COMPRESSION TEST PROCEDURE NOTE: * Before testing the engine for compression pressure, make sure that the cylinder head bolts are tightened to the specified torque values and valves are properly adjusted. * Have the engine warmed up by idling before testing. * Be sure that the battery used is in fully-charged condition. Remove the parts concerned and test the compression pres sure in the following manner. ‘= Remove the seats, fuel tank and lower cowling. (Refer to pages 7-2 and 4-5.) ‘* Remove all the spark plugs. ‘+ Fit the compression gauge in one of the plug holes, while taking care that the connection tight. * Keep the throttle grip in full-open position. ‘© While cranking the engine a few seconds with the start- er, and record the maximum gauge reading as the com- pression of that cylinder. * Repeat this procedure with the other cylinders. 09915-64510: Compression gauge 09915-63310: AdaptorMAY-24-2002 GPO 1809082 CERTIFIED P2324, HODIC MAINTENANCE ANU 1UNE-UF rHULEUUNES «cc OIL PRESSURE CHECK Check periodically the oll pressure in the engine to judge roughly the condition of the moving parts. OIL PRESSURE SPECIFICATION Above 300 kPa (3.0 kg/em?, 43 psi) eae cool ced ela ee pant a ooce Une ok eae 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 fitter * Oil leakage from the oil passage way * Damaged O-ring * Defective oll pump * Combination of above items HIGH OIL PRESSURE * Used a engine oil which is too heavy a weight * Clogged oil passage way + Combination of above items OIL PRESSURE TEST PROCEDURE Start the engine and check if the oil prassure indicator light is turned on, If it keeps on lighting, check the oil pressure indicator light circuit. If itis in good condition, check the oil pressure in the following manner. ‘* Remove the lower cowling. ‘* Remove the main oil gallery plug. «# Install the oil pressure gauge @ with adaptor in the posi- tion shown in tho figure. ‘* Worm up the engine as follows: ‘Summer 10 min, at 2000 r/min. Winter 20 min, at 2000 r/min, « After warming up, increase the engine speed to 3000 r/min. (with the engine tachometer), and read the oil pres- sure gauge. 08915-74510: Oil pressure gauge 09915-74540: Adaptor 09915-77330: Meter (for high pressure)MAY-24-2002 15:44 GPO 1S09082 CERTIFIED P.24724 TOTAL P.24MAY-24-2002 15145. GPO 1809082 CERTIFIED P.a127 ENGINE CONTENTS: ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE -- ENGINE REMOVAL AND REINSTALLATION - ENGINE REMOVAL -~ ENGINE REINSTALLATION ENGINE DISASSEMBLY ~ ENGINE COMPONENTS INSPECTION AND SERVICE CYLINDER HEAD VALVE + CAMSHAFT CAM CHAIN TENSIONER ~ CYLINDER PISTON PISTON RING PISTON PIN CONROD - CRANKSHAFT CLUTCH Ol PUMP TRANSMISSION « STARTER CLUTCH - ENGINE REASSEMBLY -~MAY-24-2002 15145 ENGINE ns GPO 1809082 CERTIFIED ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ‘The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to the page listed in each section for removal and reinstallation instructions. ENGINE CENTER Radiator Exhaust pipe/muffler Oil pressure switch Oil hose Oil filter Oil cooler Oil pan Engine oil pressure regulator Oil sump filter Carburetors .. ‘Cam chain tensioner Cylinder head cover . Cylinder head breather Water pipe (Front side! Water pipe (Rear side) . Pistons ... Starter motor Generator vevesseesesses Starter clutch cover .. Starter idle gear Starter clutch .. ENGINE LEFT SIDE See page 3 6 3 6 Gearshift lever .. Engine sprocket cover Water DUMP ssessessseeeeers Engine sprocket and drive chain .. Neutral indicator switch body . ‘See page a4 35 3-61 reese B14 310 3-10 317 3-50 347 33 3-11 and 63 3-10 and 65 310 aise 3-11 and 60 3-12 and 59 3-12 and 59 3-10 and 65 3-10 and 65 4 3-13 and 58 . 3-13 and 57 3-13 and 57 3-13 and 56 3-14 and 56 3-14 and 56 ENGINE RIGHT SIDE See page 3-14 and 54 . 3-14 and 55, Clutch cover .. Signal generator Clutch pressure, drive and driven plates .. Clutch sieeve hub 3-15 and 53 3-15 and 53 il pump driven gear . 3-16 and 52 Generator/oil pump drive gears . 3-15 and 53 Primary driven gear . 3-15 and 53 Gearshift shatt . . 3-16 and 52 Gearshift cam ghifter 1.0... 3-16 and 47 P.e227 crMAY-24-2002 15145 GPO 1809082 CERTIFIED P0327 ENGINE 3-2 eee see ENGINE REMOVAL AND REINSTALLATION ENGINE REMOVAL Before taking the engine out of the frame, wash the engine with a steam cleaner. The procedure of engine removal is sequentially explained in the following steps, and engine it stallation is effected by reversing the removal procedure. ‘© Remove the oil drain plug to drain out engine oll. ‘* Remove the front and rear seats. ‘* Remove the frame cover assembly. (See page 7-5.) : ‘+ Remove the lower cowling assembly, (See page 7-2.) « Turn the fuel cock to “OFF” position and disconnect the fuel hose @ from the fuel cock. © Remove the fuel cock mounting screws @- ‘* Remove the fuel tank mounting bolts ©. * Disconnect the fuel level indicator switch lead wire cou- pler @ and remove the fuel tank. * Disconnect the battery © lead wire terminal and battery © lead wire coupler. * Loosen the respective carburetor clamp screws (air cl side). ‘* Remove the air cleaner box by removing its mounting screws, left and right. nerMAY-24-2002 15146 GPO 1809082 CERTIFIED P0427 33 ENGINE * Disconnect the throttle cables from the throttle grip. * Disconnect the starter cable @ from the carburetor as- sembly. * Disconnect the fuel hose @ from the carburetor assembly. ‘* Loosen the respective carburetor clamp screws (engine side) and remove the carburetor assembly. * Disconnect the water hose by loosening its clamp to drain out engine coolant. * Disconnect the water hoses by loosening their clamps. ~continued—MAY-24-2002 15146 GPO 1809082 CERTIFIED P2527 ENGINE 3.4 ‘= Remove the radiator by removing its mounting bolts. * Disconnect all the spark plug caps. * Disconnect the breather hose. ‘* Remove the clutch release lever and disconnect the clutch cable.MAY-24-2002 15146 GPO 1809082 CERTIFIED P.06/27 * Disconnect the starter motor lead wire. © Disconnect the various lead wires. @ Signal generator @ Generator @ Oil pressure switch @ Neutral switch ight exhaust pipe clamp bolts. ‘* Remove the muffler mounting bolts, then remove the ex- haust pipe/muffier assembly. NOTE: When installing a new exhaust pipa/muttler connector, clean any old dried sealer from the exhaust pipe and from inside the muffler and the exhaust ges sealer should be applied to both the inside and outside of the exhaust pipe/muftler con- nector. EXHAUST GAS SEALER: PERMATEX 1372MAY-24-2882 15:47 GPO 180302 CERTIFIED ‘© Remove the gearshift lever by removing its mounting bolt. '* Remove the engine sprocket cover by removing the bolts. Ante: When installing tne engine sprocxet cover vorts, upply = small quantity of the THREAD LOCK “1342” to their threads. 99000-32050: THREAD LOCK “1342” Tightening torque: 4-7 Nem {0.4—0.7 kg-m, 3,0—5.0 lb-ft) '* Remove the engine sprocket nut while depressing the rear brake pedal. ‘© Remove the engine sprocket. NOTE: It it is difficult to remove the engine sprocket, loosen the axle nut and chain adjusting nuts ta provide additional chain slack. '* Remave the lower cowling brackets, left and right. ‘© Support the engine with a proper engine jack. * Remove the engine mounting bolts, nuts, spacers and brackets. * Gradually lower the engit sssembly. P.O727 ENGINE 3.6MAY-24-2002 15:47 GPO 1809082 CERTIFIED P.e8/27 3:7_ ENGINE ENGINE REINSTALLATION Reinstall the engine in the reverse order of engine removal. = Insert the two long bolts from left side. Install the brackets, spacers, bolts and nuts properly, as shown in the following illustration. NOTE: The engine mounting nuts are self-locking. Once the nut has been removed, it is no longer of any use. Be sure to use new nuts and tighten them to the specified torque. TIGHTENING TORQUE EM [Nem O.@ | 70-88 @.@ [70-88 LENGTH Bort @ 280 mm (11.0 in) Bolt @ 30mm (1.2 in) Bott @ 30 mm (1.2 ib ‘Spacer RH@. 65 mm (2.6 in) 7 Spacer tH ® _ ‘45 mm (1.8 in)MAY-24-2002 15:47 GPO 1809082 CERTIFIED P.e927 ‘© Replace the plug caps on the spark plugs so that their code markings correspond to the cylinder numbers arranged in the order of 1, 2, 3, and 4 from the left hand. * Locate the carburetor clamps, as shown in the illustration. Carburetor clamp position (Engine side) “6600. (Carmuretor clamp position (Air cleaner sie} ‘+ Install the gearshift lever to the gearshift shaft in the cor- rect position,MAY-24-2002 15:48 GPO 1809082 CERTIFIED P.10/27 3.9 ENGINE ‘© After remounting the engine, route wiring harnesses, ca- bles and hoses properly by referring to the sections, for wire routing, cable routing and hose routing. (See pages 8-12 through 22.) © Adjust the following items to the specification. Page * Filling engine coolant sescssessasesese 213, * Clutch cable play ........ 211 * Throttle cable play * Idling adjustment .. * Balancing carburetors * Drive chain .. © Pour 3.9L (4.1/3.4 US/Imp qt) of engine oll SAE TOW/40 graded SE or SF into the engine after overhauling engine. Start up the engine and allow it run for several minutes at idle speed. About several minutes after stopping en- gine, check that the oil level remains between the marks of cil level inspection window. Change ‘3000 ml (3.2/2.6 US/Imp at) Filter change 3300 mi (3.5/2.9 US/Imp at) (Overhaul 3900 ml (4.1/3.4 US/Imp at)MAY-24-2002 15:48 GPO 1809082 CERTIFIED P.11727 ENGINE 3.10 ENGINE DISASSEMBLY ‘© Remove the oil filter by using the special tool. 09916-40610: Oil filter wrench NOTE: Refer to page 2-9 for installation procedures. ‘= Remove the oil cooler by removing its union bolt. * Remove the inlet and outlet water pipes/hoses by remov- ing the mounting bolts and clamp screws. * Remove the cylinder head cover © by removing the bolts. NOTE: The cylinder head breather cover @) is to be removed only when replacing it or when removing the engine from the frame. 09914-25811: 6 mm ““T” type hexagon wrenchMAY-24-2002 15:48 GPO 1809082 CERTIFIED P.12/27 3-11 ENGINE ‘+ Remove the left and right oil hoses @ by removing the union bolts. * Remove the signal generator cover by removing the bolts. (09911-73730: 5 mm “"T’" type hexagon wrench ‘* After removing the spring holder bolt @ and spring @ , remove the cam chain tensioner by removing the mount- ing bolts. ‘+ Remove the left and right oll pipes by removing the bolts. ‘* Remove the four camshaft journal holders by removing the bolts. NOTE: &e sure to loosen camshaft jaumal holder bolts eventy by shifting the wrench diagonelly. ‘+ Remove the two camshafts, intake and exhaust.MAY-24-2002 15149 GPO 1809082 CERTIFIED P.13/27 ENGINE 3.12 © The cylinder head becomes free for removal when its one 6-mm bolt @and twelve 10-mm bolts are removed. 09911-74520: Long socket 12 mm 09914-24510: T-handle NOTE: When loosening the cylinder head bolts, loosen each bolt tittle by litte, in a descending order, according to the numbers. CAUTION: : Be careful not to damage the fins when removing or han- dling the cylinder head. This precaution applies to the ‘cylinder block also. * Remove the cylinder nut ®. * Firmly grip the cylinder block at both ends, and lift it straight up. If the block does not come off, lightly tap on the finless portions of the block with a plastic mallet to make the gasketed joint loose.MAY-24-2002 15149 GPO 1809082 CERTIFIED P.14/27 313 ENGINE '* Scribe the cylinder number on the head of the respective pistons. * Place a cloth beneath the piston so as not to drop any parts in the crankcase, and remove the circlip @ with long nose pliers. ‘* Draw out the piston pin. Place each piston pin in the same piston as that it was removed from. ‘* Remove the starter motor by removing the bolts. ‘© Remove the generator by removing the bolts. * Remove the starter clutch cover by removing the bolts. 09911-73730: § mm “'T”’ type hexagon wrenchMAY-24-2002 15149 GPO 1809082 CERTIFIED P.18/27 * Remove the sterter idle gear and its shaft. © Remove the starter clutch assembly. ‘= Remove the signal generator rotor by removing the bolt, 09900-00410: Hexagon wrench set = ‘* Remove the signal generator stator by removing the two screws. = Remove the clutch cover by removing the bolts. 09911-73730: 5 mm “T’” type hexagon wrench * Remove the clutch spring set bolts diagonally while hold- jing the conrod with the special tool. 09910-20116: Conrod stopper ‘+ Remove the clutch pressure plate along with its release bearing and rack.MAY-24-2002 15:58 GPO 1809082 CERTIFIED P.16/27 345 ENGINE © Flatten the lock washer of the clutch sleeve nut. © After removing the several clutch plates, remove the ‘clutch sleeve hub nut after firmly locking the clutch sleeve hub with a clutch sleeve hub holder, and then remove the remainder of clutch drive and driven plates along with the clutch sleeve hub. 09920-53740: Clutch sleeve hub holder * Remove the thrust washer @) . ‘+ With the spacer and bearing removed, the primary driven gear (integral with the clutch housing) is free to disen- gage from the primary drive gear. * Remove the primary driven gear assembly with the gener- ator/oll pump drive gears. ‘* Remove the thrust washer @ .MAY-24-2002 15:58 GPO 1809082 CERTIFIED P.17/2? ENGINE 2.16 ‘* Remove the oil pump driven gear by removing the circlip. (09900-06107: Snap ring pliers NOTE: Do not lose the cirelip, pin and washers. '* Remove the circlip and washer from the gearshift shaft. (99900-06107: Snap ring pliers ‘* Draw out the gearshitt shaft/gearshift arm @ , and then remove the cam shifter @ by removing the screws @ , nut © and arm stopper bolt ©) . 09900-09003: Impact driver set NOTE: When removing the cam shifter @), do not lose the gear shifting roller © , paw! @ . pin © and spring ®@ . © Remove the water pump by removing the mounting screws and nut. * Flatten the lock portions of the oil seal retainer and re- move it by remaving the four bolts, * Remove the neutral position indicator switch by remov- ing the screws. NOTE: Do not lose the O-ring @, switch contact @ and its spring ©.MAY-24-2002 15:58 GPO 1809082 CERTIFIED 347_ ENGINE P.18/27 ‘+ Remove the countershaft bearing retainer by removing the two screws. ‘* Remove the oil pan by removing the bolts. ‘+ Remove the oil sump filter @ by removing the two bolts. * Remove the shim @ and O-rings @ ‘* Remove the upper crankcase tightening bolts.MAY-24-2002 15!S1. GPO 1809082 CERTIFIED P.19/27 ENGINE 3-1 '* Remove the lower crankcase tightening bolts. * When removing the crankshaft tightening bolts, loosen ‘them in the descending order of numbers assigned to ‘these bolts. ‘* Make sure that all bolts are removed without fall. Ham- ‘mer lightly the lower crankcase side with a plastic ham- mer to separate the upper and lower crankcase halves and ‘then lift the latter. CAUTION: Do nat drop the crankshaft journal bearings from the lower crankcase. * Remove the crankshaft assembly from the upper crankcase. NOTE: Bear in mind that the crankshaft thrust bearings @ are located between the shaft and the case. * Remove the two dampers @ and cam chain guide @ . * Remove the O-ring @ - = Remove the countershaft assembly @ and driveshatt sembly © - ‘ 09)MAY-24-2002 15!S1. GPO 1809082 CERTIFIED 3:19 ENGINE P2027 NOTE: Do not lose the C-rings © and bearing pins @ . ‘* Hold the gearshift forks by hand while drawing out the gearshift fork shafts from the lower crankcase. * Remove the gearshift cam stopper plate @ by removing the bolt while holding the gearshift cam with an adjuster wrench. * Remove the washer @ . ‘+ Draw out the gearshift cam with bearing from the lower crankcase. Note: Rotate the bearing @ on the gearshift cam by hand to in- ‘spect for abnormal noise and smooth rotation. Replace the bearing it there is anything unusual.P.2127 MAY-24-2002 15!51 GPO 1809082 CERTIFIED ENGINE 3.20 NOTE: When replacing the gearshift cam stopper bolt @ , apply 2 small quantity of THREAD LOCK “7342” to the bolt. 99000-32050: THREAD LOCK “1342” ‘+ Remove the oil pump by removing the mounting bolts. 09900-00410: Hexagon wrench set * Remove the oil pump O-rings and dowel pins.MAY-24-2882 15:52 GPO 180302 CERTIFIED P2227 3:21 ENGINE ENGINE COMPONENTS INSPECTION AND SERVICE CYLINDER HEAD SERVICE C CAUTION: Be sure to identify each removed part as to its location, and ‘out in groups designated as “No.1”, “No.2”, Inlet’, so that each will be restored to the origi- nal lacation during assembly. ( NOTE: If valve guides have to be removed for replacement after inspecting related parts, carry out the steps shown in valve guide servicing. * Remove the tappets and shims by fingers or magnetic hand. 09916-14510: Valve lifter 09916-14620: Valve lifter attachment 09916-84511: Tweezers * Remove the valve spring retainer, valve spring and valve ( spring seat. * Pull out the valve from the other side,MAY-24-2882 15:52 GPO 180302 CERTIFIED P.2327 CYLINDER HEAD DISTORTION Decarbonize the combustion chambers. Check the gasketed surface of the cylinder head for distor- tion with a straightedge and thickness gauge, taking a clear- ance reading at several places indicated. If the largest reading at any position of the straightedge exceads the limit, replace the cylinder head. 09900-20803: Thickness gauge Service Limit: 0.2 mm (0.008 in.) VALVE STEM RUNOUT Support the valve with '“V"’ blocks, as shown, and check its runout with a dial gauge. The valve must be replaced if the runout exceeds the limit. 09900-20606: Dial gauge (1/100 mm) 09900-20701: Magnetic stand 09900-21304: V-block (100 mm) Service Limit: 0.08 mm (0.002 in) VALVE HEAD RADIAL RUNOUT Place the dial gauge at right angles to the valve head face, and measure the valve head radial runout. If it measures more than the limit, replace the valve. 09900-20606: Dial gauge (1/100 mm) 09900-20701; Magnetic stand Service Limit: 0.03 mm (0.001 in.) VALVE FACE WEAR Visually inspect each valve for wear of its seating face. Replace any valve with an abnormally worn face. The thick- ness ( decreases as the wear of the face advances. Measure the thickness ang, if the thickness is found to have been reduced to the limit, replace it. 09900-20102: Vernier calipers Service Limit D: 0.5 mm (0.02 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, by positioning the dial gauge as shown. If the deflection measured exceeds it, (see below) 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 valve: 35 mm (0.014 in) am, See SB) BO TOSMAY-24-2002 15:52 GPO 1809082 CERTIFIED P2427 3.23 ENGINE VALVE STEM WEAR If the valve stem is worn down to the limit, as measured with a micrometer, where the clearance is found to be in excess of the limit indicatad, replace the valve; if the stem is within the limit, then replace the guide. After replacing vaive or guide, be sure to recheck the clearance. 09900-20205: Micrometer (0—25 mm) Standard Intake valves: 4.465—4.480 mm (0.1758—0.1764 in) Exhaust valves: 4.455—4.470 mm (0.1764—0.1760 in) VALVE GUIDE SERVICING * Using the vaive guide remover @ , drive the valve guide out toward the intake or exhaust camshaft side. 09916-43210: Valve guide remover/installer removed valve guide subassemblies. * Only oversized valve guides are available as replacement parts. (Part No. 11115-17E70) * Re-finish the valve guide holes in cylinder head with the reamer and handle. 09916-34580: Valve guide reamer 09916-34542: Reamer handle * Oil the stem hole, too, of each valve guide and drive the guide into the guide hole with the valve guide installer and attachment. 09916-43210: Valve guide removeriinstal Valve 09916-43230: Attachment ee cytes feed CAUTION: a Failure to oil the valve guide hole before driving the new guide into place many result in a damaged guide or head. ‘* After fitting the vaive guides, re-finish their guiding boras with the reamer. Be sure to clean and oil the guides after reaming, 09916-33210: Vaive guide reamer 09916-34542: Reamer handleMAY-24-2002 15:53. GPO 1809082 CERTIFIED P2527 ENGINE 3.24 VALVE SEAT WIDTH '* Coat the valve seat uniformly with Prussian blue. Fit the valve and tap the coated seat with the valve face in a rotating manner, in order to obtain a clear impression of the seating contact. In this operation, use the valve lap- per to hold the velve head. ‘+ The ring-like dye impression left on the valve face must be continuous-without any break. In addition, the width of the dye ring, which is the visualized seat “width”, must be within the following specification: Standard Valve seat width @: 0.9—1.1 mm (0.035—0.043 tei ing VALVE SEAT SERVICING The valve seats for both intake and exhaust valves are machined to four different angles. (The seat contact surface is cur 45°.) er requirement is not met, correct the seat by servic follows: INTAKE EXHAUST 45° [| N-116 or N-122 | 45° |_N-116 or N-122 30° N-126 15% |_N-120 or N-121 60° N-114 [ Valve seat cutter: (N-111), {N-126), (N-121}, (N-122), {N-116) and (N-120) Solid pilot: (N-100-4.5) NOTE: The valve seat contact area must be inspected after each cut. ‘+ Insert the solid pilot © with e slight rotation. Seat the pilot snugly. Install the 45° cutter, attachment and T-handle. * Using the 45° cutter, descale and clean up the seat with fone or two turns. ‘* Inspect the seat by the previously described seat width measurement procedure. If the seat is pitted or bumed, additional seat conditioning with the 45° cutter is required. 1m amount necessary from the seat to provent the possibility of the tappet shim replacement.MAY-24-2002 15:53. GPO 1809082 CERTIFIED P.26/27 oe if the contact area is too high on the valve, or if itis too [Contact erea toe high and too wide, use the 15° cutter (for exhaust side) and 30°/60° | wide on face of valve C cutters (for intake side) to lower and narrow the contact area. If the contact area is too low or too narrow, use the 45° — [Contact area too low and #00 cutter to raise and widen the contact area. arrow on face of vaive Cc '» 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: DO NOT use tapping compound after the final cut is made. The finished valve seat should have a velvety smooth fin- ish and not a highly polished or shiny finish. This will pro- vide a soft surface for the final seating of the valve which will occur during 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 gasoline. NOTE: After servicing the valve seats, be sure to check the tappet clearance after the cylinder head has been reinstalled. (see ¢ page 2-4.)MAY-24-2002 15:53. GPO 1809082 CERTIFIED P.272? ENGINE “$20 VALVE SPRING The force of the coll spring keaps the valve seat tight. Weakened spring result in reduced engine power output, and often account for the chattering noise coming from the valve mechanism. Check the valve spring for proper strength by measuring its free length and also by the force required to compress it. If the spring length is less than the service limit, or if the force required to compress the spring does not fall within the range specified, replace the spring. Valve spring free length Service Limit: 43.0 mm (1.69 in) Valve spring tension Standard: 18.6—21.4 kg/38 mm (41,0—47.2 bs/1.5 in) REASSEMBLY * Oil each oll seal, and press-fit them into position with the valve guide installer. 09916-43210: Valve quide remover/installer CAUTION: Do not reuse the oll seals. * Install each valve spring seat. ¢ Insert the valves, with their stems coated with high quality molybdenum disulfide lubricant (SUZUKI MOLY PASTE) all around and along the full stem length without any break. CAUTION: When inserting each valve, take care not to damage the lip of the oil seal. 99000-25140: SUZUKI MOLY PASTE 18,6—21.4 kg & TOTAL P.27MAY-24-2002 16144 GPO 1809082 CERTIFIED 3:27_ ENGINE P.a1719 * Install the valve spring with the smail-pitch portion @ facing cylinder head. @Large-pitch portion. ‘+ Put on the valve spring retainer and, using the valve lifter, press down the spring, fit the cotter halvas to the stem ‘end, and release the lifter to allow the cotter @ to wedge in between retainer and stem. Be sure that the rounded lip @ of the cotter fits snugly into the groove @ in the stem end, 09916-14510: Valve lifter 09916-14820: Valve lifter attachment 09916-84511; Tweezers CAUTION: Be sure to restore each spring, valve, shim and tappet to their original positions. NOTE: Apply engine oil to the shim and tappet before fitting them. CAMSHAFT Both camshafts should be checked for runout and also for ‘wear of cams and journals if the engine has been noted as giving abnormal noise or vibration or lack power output. Any of these conditions may be caused by camshafts worn down or distorted to the service limit. Ih. open [In. close [Ex. open|ex. close] upwaRD B®. ® Painted white E-04, gee | 62° | 55° | 29° E-18 and 33 3° ese | 59° | 22° The exhaust camshaft can be distinguished from that of the intake by the embossed letters “EX” (for exhaust) as against letters “IN” (for intake). Similarly, the right end can be distinguished by the notch from the left end. LD. code ie | Ex E0e op fo E18 and 33 a 03,03 and others| © | ®MAY-24-2002 16145 GPO 1809082 CERTIFIED P.e2719 ENGINE CAM WEAR Worn-down cams are often the cause of mistimed vaive operation resulting in reduced power output. The limit of cam wear is specified for both intake and ex- haust cams in terms of cam height @), which is to be mea: ured with @ micrometer. Replace camshafts if found worn down to the limit 09900-20202: Micrometer (25-50 mm) Cam height @ Service Limit intake cams | Exhaust came £02,038, 36.02 mm 36.61 mm and others (1.418 in} (1.402 in) 34.25 mm 33.83 mm E18 and 33 | (1.348 in) (1,382 in) 36.02 mm 36.61 mm ea (1.418 in} (1.402 in} CAMSHAFT JOURNAL WEAR Determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft in- stalled in place. Use the plastigauge © to read the clear- ance at the widest portion, which is specified as follows: Camshatt-Journal oll clearance (IN & EX) Service Limit: 0.150 mm {0.0059 in) 09900-22301: Plastigauge NOTE: Install each holder to their original positions. (page 3-62.) Tighten the camshaft holder bolts evenly and diagonally to the specified torque. Tightening torque: B—12 N-m (0.8—1.2 kg-m, 6.0-8.5 Ib-ft) NOTE: Do not rotate the camshafts with the plastigauge in place. Remove the camshaft holders, and read the width of the compressed plastigauge with envelope scale. This measure- ment should be taken at the widest part.MAY-24-2882 16:45 GPO 180302 CERTIFIED P2319 If the camshaft journal oil clearance measured 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. Standard Journal holder 1.D, (IN & EX): 22.012—22.025 mm (0.8666—0.8671 in) (09800-20205: Micrometer (0-25 mm) 3 Standard Camshaft journal O.D. {IN & EX): 21.959—21.980 mm {0.8645—0.8654 in) CAMSHAFT RUNOUT Measure the runout with a dial gauge. Replace the camshaft if the runout exceeds the limit. i Camshaft runout (IN & EX) Service Limit: 0.1 mm (0.004 in) (09900-20606: Dial gauge (1/100 mm, 10 mm) 09900-20701: Magnetic stand 09900-21304: V-block (100 mm) CAM SPROCKET ‘The fixed position of each cam sprocket on each camshaft is determined by arrow mark “3” (on INTAKE sprocket) or arrow marks "1" and "2" (on EXHAUST sprocket) locat- ed {as shown) in reference to the notch ( in the right end of each camshaft. REASSEMBLY * Apply THREAD LOCK SUPER “1303” to the threads of (2.4-2.6 kg-m, 17.5—19.0 b-ft)MAY-24-2002 16145 GPO 1809082 CERTIFIED P.04719 ENGINE 3.30 EEE ead CAM CHAIN TENSIONER The cam chain tensioner is maintained at the proper tension by an automatically adjusted tensioner. Unlock the ratchet mechanism @ , and move the push rod @ in place to see if it slides smoothly. If any stickiness is not- ed or ratchet mechanism is faulty, replace the cam chai tensioner assembly with a new ons CAM CHAIN GUIDE NOTE: When replacing the cam chain guides, apply SUZUKI) THREAD LOCK SUPER “1303” to threads of bolt and screws. 99000-32030: THREAD LOCK SUPER ‘"1303" Cam chain guide mounting bok: | 4-7 Nim (0.40.7 kg-m, 3.0—5.0 Ib-ft) CYLINDER BLOCK DISTORTION Check the gasketed surface of the cylinder block for tion with a straightedge and thickness gauge, taking a clear- ance reading at several places as indicated. If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder block. 09900-20803: Thickness gauge Cylinder distortion Service Limit: 0.2 mm (0.008 in) » utMAY-24-2002 16146 GPO 1809082 CERTIFIED 3:31_ewt P.25/19 CYLINDER BORE ‘Measure the cylinder bore diameter at six places. It any one of the measurements exceeds the limit, overhaul the cylinder ‘and replace the piston with an oversize piston. The remain- ing cylinders must be also rebored accordingly. Otherwise, the imbalance might cause excess vibr Cylinder bore Service Limit: 65.075 mm (2.6620 in) 09900-20508: Cylinder gauge set PISTON DIAMETER Using a micrometer, measure the piston's outside diameter at the place shown in Fig. If the measurement is less than ‘the limit, replace the piston. Service Limit: 64.880 mm (2.5543 in) 09900-20203: Micrometer (50—75 mm) PISTON-CYLINDER CLEARANCE ‘As a result of the above measurement, if the piston clear- ‘ance exceeds the following limit, overhaul the cylinder and use an oversize piston, or replace both cylinder and piston. Service Limit: 0.12 mm (0.0047 in} Piston oversize: 0.5, 1.0 mm PISTON RING-GROOVE CLEARANCE Using a thickness gauge, measure the side clearances of the ‘Ist and 2nd rings. if any of the clearances exceeds the limit, replace both piston and piston rings. 09900-20803: Thickness gauge Piston ring-groove clearance Sarvice Limit ‘Ist & 2nd: 0.18 mm (0.007 in)MAY-24-2002 16146 GPO 1809082 CERTIFIED P.06/19 ENGINE 3-32 Piston ring groove width 830.85 mm (0.032—0.033 in} 820.84 mm (0.032—0.033 in) Oi : 1.51—1,53 mm (0.089—0.060 in) Piston ring thickness Standard ‘1st & 2nd: 0.77—0.79 mm (0.030—0.031 in) PISTON RING FREE END GAP AND PISTON RING END GAP Before installing piston rings, measure the free end gap of each ring using vernier calipers. Next, fit the ring in the cylinder, and measure each ring end gap using a thickness gauge. If any ring has en excess end gap, replace the ring. Piston ring free end gap joo’ umie 18%! 8:0 mm (0.24 In) Service Limit aq: 6.4 mm (0.25 in} 09800-20102: Vernier calipers Piston ring end gap Service Limit ‘st & 2nd: 0.5 mm (0.02 in) 09900-20803: Thickness gauge Oversize piston ring ‘The following two types of oversize piston ring are used. They bear the following identification numbers. optional parts. They bear the following identification marks. SIZE COLOR STD NIL, 0.5 mm 0. Painted red 1.0 mm 0.! Painted yellow Oversize side rail Just measure out side diameter to identify the size. Ast 2nd S 0.5 mm 50 50 1.0 mm 100 100 Oversize oi ring <2 The following two types of oversize oil ring are available as > oerMAY-24-2002 16146 GPO 1809082 CERTIFIED ENGINE. P.a7719 333 PISTON PIN AND PIN BORE Using a small bore gauge, measure the piston pin bore in- side diameter, and using a micrometer, measure the piston pin outside diameter. If the difference between these two meesurements is more than the limits, replace both piston and piston pin. Piston pin bore I.D. Service Li 6.030 mm (0.6311 in) 09900-20602: Dial gauge (1/1000 mm, 1 mm) 09900-22401: Small bore gauge (10-18 mm) Using a micrometer, measure the piston pin outside diameter at three positions. Piston pin 0.D. mm (1 8744 int Using a small bore gauge, measure the conrod small end in- side diameter. (09900-20602: Dial gauge (1/1000 mm, 1 mm) (09900-22401; Small bore gauge (10-18 mm} Conrod small end 1.D. Service Limit: 16.040 mm (0.6315 in} H the conrod small end inside diameter exceeds the above- mentioned limit, replace the conrod. CONROD BIG END SIDE CLEARANCE Check the conrod side clearance by using @ thickness gauge. If the clearance exceeds the limit, replace conrod or crankshaft. ‘Service Limit: 0.3 mm (0.01 in) 09900-20803: Thickness gauge Standard Big end width: 20,95~21.00 mm (0.825—0.827 in) Standard Crank pin width: 21.10—21.15 mm (0.831—0.833 In) (09900-20205: Micrometer (0—25 mm) 09900-20605: Dial calipers (10~34 mm)MAY-24-2002 16147 GPO 1809082 CERTIFIED P.28/19 ENGINE 3: CONROD-CRANK PIN BEARING SELECTION * Remove the bearing cap bolts, and tap the bearing cap lightly with plastic hammer to remove the bearing cap. orate tne rods, and mark them to identify the cylinder | &{=—Umy position. « Inspect the bearing surfaces for any sign of fusion, pit- fom ting, burn, or flaws. If any, replace them with a specified set of bearings. * Place plastigauge axially on the crank pin avoiding the oil hole, at TDC or BDC side as shown. «+ Tighten the bearing cap bolts with two-step torque values. Initial tightening torque: 32—37 N-m (3.2—3.7 kg-m, 23.0—-27.0 Ib-ft) 5—68 N-m (6.5—-6.8 kg-m, 47.0—49.0 lb-ft) 09900-22301; Plastigauge NOTE: When fitting bearing cap to crank pin, be sure to discriminate ‘one end from the other, namely front and rear. NOTE: Never rotate the crankshaft or conrod when a piece of plastigauge is in the clearance. Final tightening torque: + Remove the caps, and measure the width of compressed plastigauge with envelope scale. This measurement should be taken at the widest part, Crank pin bearing oil clearance ‘Standard: 0.032—0.056 mm {0.0013—0.0022 in) Service Limit: 0.080 mm (0.0031 in) © If oil clearance exceeds the service fied bearings from the bearing selection tabl * Check the corresponding conrod |.D. code number @) , Oy or "2",MAY-24-2002 16147 GPO 1809082 CERTIFIED P.29719 3.35 ENGINE * Check the corresponding crank pin 0.D. code number O71", "2" oF "3" Bearing selection table Crank pin 0.0. @ Code 1 2 3 Conred 1 Green | Black | Brown . 10. @ a Black | Brown | Yellow Conrod 1.D. specification Code .D. specification ; '37.000—37.008 mm (1.4567 — 1.4570 in) 2 '37,008—37.016 mm (1.4570—1,4573 in) Crank pin 0.D. specification Code 0.D. specification 33.992—34.000 mm (1.3383~1.3386 in) 33.984—33.992 mm (1,3380~1.3383 in} 33,976—33.984 mm (1.3376—1,3380 in) 09900-20202: Micrometer {25-50 mm) 1 2 3 Bearing thickness Color (Part No.) Thickness: Green 1.480—1.484 mm {12164-18E00-080) (0.0583—0.0584 in) Black 1.484—1.488 mm (12164-18500-080) (0.0584-0,0586 in) Brown 1.488— 1.492 mm (12164-18E00-0C0) {0.0586—0.0587 in) Yellow 1.492— 1.496 mm (12164-18E00-0D0) {0.0587—0.0589 in) CAUTION: Bearing should be replaced as a set. BEARING ASSEMBLY * When fitting the bearings to the bearing cap and conrod, be sure to fix the stopper part first, and press in the other end.MAY-24-2002 16147 GPO 1809082 CERTIFIED P.10/19 ENGINE 3.31 = Apply engine oil or SUZUKI MOLY PASTE to the crank pin and bearing surface. 99000-25140: SUZUKI MOLY PASTE ‘+ When mounting the conrod on the crankshaft, make sure that numeral figure @ of the conrod faces rearward. + Tighten the bearing cap bolts with specified torque. Initial tightening torque: 32—37 N-m (3.2—3.7 kgrm, 23.0—27.0 tb-ft) Final tightening torque : 65—68 N-m (6.5—6.8 kg-m, 47.0—49.0 lb-ft) * Check the conrad movement for smooth turning. CRANKCASE-CRANKSHAFT BEARING SELECTION © Inspect each bearing of upper and lower crankcases for any damage. * Place the plastigauge on each crankshaft journal in the usual manner. 09900-22301: Plastigauge NOTE: Do not place the plastigauge on the oil hole, and do not ro~ tate the shaft when plastigauge is in place. * Mate the lower crankcase with the upper crankcase, and tighten the crankshaft tightening bolts with specified tor- que value in the indicated order. Tightening torque | Initial Tightening | Final Tightening 13 Nem 24-28 Nem 9 mm bolt 1,3 kg-m 2.4-2.8 kg-m 9.5 lb-ft 17.5-20.0 lb-ftMAY-24-2002 16148 GPO 1809082 CERTIFIED P.1119 3.37_ENGINE * Remove the lower crankcase, and measure the width of compressed plastigauge in the usual manner. Crank journal bearing oil clearance Standard: 0.020~-0.044 mm (0.0008—0.0017 in) 0.08 mm (0.0031 in) ‘* If the width at the widest part exceeds the limit, replace the set of bearings with new ones by referring to the selec- tion table. '* Check the corresponding crankcase journal |.D. code num- ber @ , ‘“A” or ““B’ which are stamped on the rear of upper crankcase. ‘© Check the corresponding crankshaft journal 0.D. code number @ , “A”, “B" or ’C"” which are stamped on the crankshaft. Bearing selection table * a Crankshaft 0.D. @ ' ode A A c Crankcaso| A Green | Black | Brown 10. B Black | Brown | Yellow ‘specification LD. specification '37.000—37.008 mm (1.4567—1.4570 in) 8 37,008—37.016 mm (1.4570—1.4573 in) Crankshaft journal O.D. specification Code 0.D. specification '33.992—34.000 mm o {1.3383—1.3386 in) : ‘33,984 33,992 mm (1.3380—1.3383 in) - 33.976—-33.984 mm (1,3376— 1.3380 in) 09900-20202: Micrometer (25-50 mm)MAY-24-2002 16148 GPO 1809082 CERTIFIED P.12/19 Bearing thickness specification (Grooved bearing with oil hole ..... For lower case) Color (Part No.) Specification Green 7.486—1.490 mm (12229-17£00-0A0) (0.0585—0,0687 in) Black 1,490—1.494 mm (12229-17E00-080) {0.0587—0,0588 in) Brown 1.494—1.498 mm {12229-17£00-0CO) {0.0588—0.0590 in) Yellow 1.498—1.502 mm (12229-17E00-0D0) (0.0590—0,0591 in) NOTE: * Grooved bearings have the same specification as the Grooved bearing with oil hole. * These parts numbers are shown as follows. 12229-17E10-XXX. (Grooved bearing) CRANKSHAFT THRUST CLEARANCE * With the crankshaft, right-side thrust bearing and left-side thrust bearing inserted in the upper crankcase, use a ‘thickness gauge to measure the thrust clearance on the left-side. @: Right-side thrust bearing ©; Left-side thrust bearing NOTE: Push the crankshaft to the left-side, so that there is no clear- ance on the right-side thrust besring. ‘Thrust clearance Standard: 0,055—0.110 mm (0.0022—0.0043 in) Hf the thrust clearance exceeds the standard range, adjust the thrust clearance by the following procedures: ‘* Remove the right-side thrust bearing and measure its ‘thickness with a micrometer. If the thickness of the right- side thrust bearing is below standard, replace with a new bearing and once again perform the thrust clearance meas- urement listed above, checking to make sure it is within standard. Right-side thrust bearing thickness Standard: 2.425— 2,450 mm (0.0955—0.0965 in) SY Color code Color cade roaved bearing with oll hole (For lower case)MAY-24-2002 16148 GPO 1809082 CERTIFIED 3:39 ENGINE P.1319 ‘+ If the right-side thrust bearing is within the standard range, reinsert the right-side thrust bearing and remove the left- side thrust bearing. + As shown in the illustration, use a thickness gauge to measure the clearance before inserting of the left-side thrust bearing, and select a left-side thrust bearing from the selection table. Thrust beating selection table 5 (0.0957—0.0969 in) | (12228-17E00-0A0) | (0.0925—~ Clearance before : inserting left-side anime oe Thrust clearance thrust bearing 7 (2.560—2.585 mm White (2.475—2,500 mm 0,060—0,.110 mm {0.1008—0.1018 in) | (12228-17E00-OFO) (0,0974—0,0984 in) | (0.0024—0.0043 in) 2.535-—-2.560 mm Yellow 2.450—2.475 mm 0.060—0.110 mm {0.0998—0,1008 in) | (12228-17EOO-OEO) | {0.0965—0.0974 in) | (0.0024—0.0043 in) 2.510—2.535 mm Green 2.425-2,450 mm | 0,060-0.110 mm. (0,0888—0,0998 in) | (12228-1700-000) | (0.0955--0,0985 in) | (0.0024—0.0043 ini (2.485—2.510 mm Blue (2.400—2.425 mm 0.060—0.110 mm (0.0978—0.0988 in) | (12228-17E00-0CO) ).0955 in) | (0.0024—0.0043 in) (2.460—2.485 mm Black 2.400 mm 0.060—0.110 mm (0.0969—0.0978 in) | (12228-17E00-OB0) ).0945 ind | (0.0024—0.0043 in} (2.430—2.460 mm Red (2.350—2.375 mm 0.055—0.110 mm 1.0935 in) | (0.0022—0.0043 in} * After selecting a left-side thrust bearing, insert it and again perform the thrust clearance measurement to make sure it falls within the standard range. NOTE: Right-side thrust bearing has the same specification as the GREEN (12226-17E00-0D0) of left-side thrust bearing. CRANKSHAFT RUNOUT ‘Support the crankshaft with ‘’V blocks as shown, with the ‘two end journals resting on the blocks, Set up the dial gauge, as shown, and rotate the crankshaft slowly to read the runout. Replace the crankshaft if the runout is greater than the limit. 08900-20606: Dial gauge (1/100 mm, 10 mm} 99900-20701; Magnetic stand 09900-21304: V-block (100 mm) Crankshaft runout Service Limit: 0.05 mm (0.002 in) Color coreMAY-24-2002 16149 GPO 1809082 CERTIFIED P.1419 ENGINE 3.40 CLUTCH DRIVE AND DRIVEN PLATES “These plates are expendable: they are meant to be replaced when found worn down or distorted to the respective use a vernier calipers to check thickness and a thickness gauge and surface plate to check distortion. 09900-20102: Vernier calipers {200 mm) 09900-20803: Thickness gauge Drive plate thickness Standard: 2.12—2.28 mm (0.083—0.090 in) Service Limit: 1.82 mm (0.072 in} Driven plate distortion Service Limit: 0.10 mm (0.004 in) CLUTCH SPRING FREE LENGTH Measure the free length of each coil spring with vernier calipers, and compare the elastic strength of each with the specified limit. Replace all the springs if any one of springs is not within the limit. (09900-20102: Vernier calipers (200 mm) Clutch spring free length Service Limit: 47.5 mm (1.87 in) CLUTCH RELEASE BEARING Inspect the clutch release bearing for any abnormality to de- cide whether it can be reused or should be replaced. Smooth engagement and disengagement of the clutch de- pends much on the condition of this bearing. CLUTCH RELEASE PINION AND RACK Rotate the clutch release pinion by hand to inspect for a smooth rotation. If a large resistance is felt to rotation, i ‘spect the pinion and rack for damage or wear. If the defect is found, replace them as a set. OIL PUMP CAUTION: Do not attempt to disassemble the oil pump assembly. The oil pump is available only as an assembly.MAY-24-2002 16149 3.41_ ENGINE GPO 1809082 CERTIFIED P.15/19 TRANSMISSION DISASSEMBLY © Disassemble the transmi ion gears as shown in the illustration. Q Low ativan goat © Sra/ath ave gears Top drive gear 2nd drive gear ‘Th1g42: Apply THREAD LOCK "1342". Tightening torque @®: 100=130 Nem (10.0-13.0 kgm, 72,5-~94.0 lb-ft}MAY-24-2002 16149 GPO 1809082 CERTIFIED P.16/19 ENGINE 9.42 REASSEMBLY Assemble the countershaft and driveshaft in the reverse ord- er of disassembly. Pay attention to the following points: NOTE: + Before installing the gears, rotate the bearing by hand to inspect for abnormal noise and smooth rotation. Replace the bearing if there is anything unusual. + Before installing the gears, lightly coat moly paste or en gine oi to the driveshaft and countershaft. * Before installing the oil seal, apply grease to the oil seal ip. 99000-25140; SUZUKI MOLY PASTE 99000-25030: SUZUKI SUPER GREASE “ CAUTION: * Never reuse a circlip. After a circlip has been removed from a shaft, It should be discarded, a new circlip must be installed. * When installing a new circlip, care must be taken not to ‘expand the end gap larger than required to slip the circlip cover the shaft. eg: * After installing a circlip, always insure that it is completely seated in its groove and securely fitted. NOTE: In reassembling the transmission, attention must be given to the locations and positions of washers and ciralips. The cross sectional view given here will serve as 2 reference for correctly mounting the gears, washers and circlips. (Refer to page 3-43.) ‘* When installing a new circlip, pay attention to the direc- tion of the circlip. Fit it to the side where the thrust is as shown in the illustration. a ‘+ When installing the gear bushing onto the shaft, align the shaft oil hole @ with the bushing oil hole @ .MAY-24-2002 16158 GPO 1809082 CERTIFIED P.17719 3.43 ENGINE aducoon Za wo 06 é (000006 10,2. b “OOCB00 Of 'MAY-24-2002 16158 GPO 1809082 CERTIFIED GEARSHIFT FORK-GROOVE CLEARANCE Using a thickness gauge, check the gearshift fork clearance in the groove of its gear. The clearance for each of the three gearshift forks plays an important role in the smoothness and positiveness of the shifting action. Gearshift fork-Groove clearance Standard — : 0.10—0,30 mm (0.004—0.012 in} Service Limit: 0.50 mm (0.020 in} If the clearance checked is noted to exceed the fied, replace the fork or its gear, or both. 09900-20803: Thickness gauge 09900-20102: Vernier calipers it speck Shift fork groove width Standard: 5.00—5.10 mm (0,197—0.201 in} Shift fork thickness Standard: 4.80—4.90 mm (0.189—0.193 in) ecking clearance hacking thicknessMAY-24-2002 16158 GPO 1809082 CERTIFIED 3:45_ ENGINE P.19719 STARTER CLUTCH DISASSEMBLY AND INSPECTION * Hold the starter clutch shaft to use a vise and appropri- ate pieces of soft metals, and remove the nut as shown the Fig. cauTio! This is a left-hand thread nut. ‘* Remove the generator driven gear assembly. * Inspect the dampers for wear and damage. If any defects are found, replace the dampers as a set. * Inspect the starter clutch and its contacting surface of the starter driven gear for wear or damage. If they are found to be damaged, replace them with new ones. ‘* Remove the starter clutch and its driven gear. © Remove the driven gear from the starter clutch. ‘* Remove the circlip from the starter clutch shaft. 09900-06107: Snap ring pliers TOTAL P.19MAY-24-2002 16123 GPO 1809082 CERTIFIED * Remove the bearing with a bearing puller. NOTE: Before removing the bearing, rotate the outer race by hand to inspect for abnormal noise and smooth rotation. CAUTION: ‘The removed bearing should be replaced with a new one. REASSEMBLY Assemble the starter clutch in the reverse order of disas- sembly. Pay attention to the following points: NOTE: Apply engine oil to each starter clutch part before reas- sembling. ‘* Install the bearing with a bearing installer. 09951-16080: Bearing installer oA Tightening torque Trem | Nm Tb-ft ® | 40-60 29.0—43.5 @ | 8-2 6.0-8.5 Th1303: Apply THREAD LOCK SUPER “1303”.MAY-24-2882 16:23 GPO 180302 CERTIFIED P.@2/21 3.47 EW ENGINE REASSEMBLY The engine is reassembled by carrying out the steps of disassembly in the reversed order, but there ‘are a number of steps which demand special descriptions or precautionary measures. NOTE: Apply engine oil to each running and sliding part before reassembling. * Fit the O-rings (@ ,@ and @ ) and dowel pins @) to the correct positions, as shown in the Figs. CAUTION: Replace the O-rings with new ones to prevent oil leakage. ‘* Install the oll pump to the lower crankcase with three bolts and tighten them to the specified torque. NOTE: Apply a small quantity of THREAD LOCK “1342” to the bolts. 99000-32050: THREAD LOCK “1342” Tightening torque: 8—12 N-m (0.8—1.2 kg-m, 6.0—8.5 lb-ft) 5 NOTE: 5 2) Check the oil jets (@ and @) fitted on the lower crankcase for clogging. C Each oil jt can be distinguished by the numbers and colors. (2) © Oil jor : Number 12, Yellow ee © Oil jet... ..........Number 14, White Install the gearshift cam related parts. @ Washer @ Gearshift cam stopper plate @ Bott NOTE: When installing the gearshift cam stopper plate @ , apply 2 small quantity of THREAD LOCK 1342” to its bolt 3) 99000-32050: THREAD LOCK "1342" * Position the gearshift cam as shown in Fig. so that the gearshift forks and transmission can be installed easily.MAY-24-2002 16124 GPO 1809082 CERTIFIED P2321 ENGINE 348 * Install the gearshift forks to the crankcase in the correct, positions and directions. @ For 3rd/4th drive gears @ For Top driven gear © For 5th driven gear * Fit the bearing pins @ and C-rings © on the upper crankcase. ‘© Install the countershaft assembly and driveshaft assem- bly on the upper crankcase. NOTE: * Be sure to install the bearing dowel pins © in the respec tive positions. * Install the countershaft end cap to the position @ « + Make sure that the countershaft turns freely while hold- ing the driveshaft. If not, shift the gear which is engaged to the neutral position. NOTE: Before fitting the crankshaft joumal bearings, check the noz- zles @ fitted on the upper crankcase for clogging. © Nozzle (4 pes) ...--sesss-+ For upper case ‘+ When fitting the crankshaft journal bearings to the upper and lower crankcases, be sure to fix the stopper part @) first and press the other end. (Refer to page 3-38.) cauTio Do not touch the bearing surfaces with your hands. Grasp by the edge of the bearing shell.MAY-24-2002 16124 GPO 1809082 CERTIFIED 3.49, ENGINE P.e421 # Install the cam chain guide @ and two dampers @ properly. NOTE: Be sure to face the arrow mark on the damper to the front and reer, not to the left and right. * Fit the O-ring @ . CAUTION: Replace the O-ring with a new one to prevent oil leakage. * Before installing the crankshaft, apply SUZUKI MOLY PASTE to each journal bearing lightly. 99000-25140: SUZUKI MOLY PASTE ‘© Install the crankshaft with the cam chain to the upper crankcase, ¢ insert the right and left-thrust bearings with oil grooved facing the crank web. (Refer to page 3-38.) * Clean the mating surfaces of the crankcases before matching the upper and lower ones. * Install the dowel pins to the upper crankcase. * Apply SUZUKI BOND NO. 12078 to the mating surface of the lower crankcase and crankshaft left end cap in the following procedure. 99104-31140: SUZUKI BOND NO, 1207B Nore: Use of SUZUKI BOND NO. 12078 is as follows: * Make surfaces free trom moisture, oll, dust and other for- eign materials. * Spread on surfaces thinly to form an even layer, and as- semble the cases within few minutes. * Take extreme care not to apply any BOND NO. 12078 to the bearing surfaces. + Apply to cormered surface as it forms 2 comparatively thick film. ‘* Tighten the crankshaft tightening 9-mm bolts in ascend- ing order of numbers assigned to these bolts, tightening each bolt a little at a time to equalize the pressure. Tight- en the lower and upper crankcase tightening bolts to the specified torque values.MAY-24-2002 16125 GPO 1809082 CERTIFIED P.eS21 « Fit the new gaskets to the lower crankcase bolts @cor- rectly as shown in the Fig. CAUTION: Use a new gasket to prevent oil leakage. 09900-00410: Hexagon bit wrench set «Fit the engine ground wire to the correct position as shown in the Fig. © Fita new gasket to the upper crankcase bolt @)correctly as shown in the Fig. CAUTION: Use @ new gasket to prevent oil leakage. + Fit a new O-ting @ and shim @ . © Fit a new O-ring @ and install the oil sump filter to the lower crankcase. CAUTION: Replace the O-rings with new ones to prevent oil leakage. '* Seat the washer and install the oil pressure regulator to the oil pen and tighten it to the specified torque. Tightening torque: 25—30 N-m (2.5—3.0 kg-m, 18.0+21.5 tb-ft)MAY-24-2002 16125 GPO 1809082 CERTIFIED P0621 351_ ENGINE NOTE: When replacing the oil prassure switch, apply SUZUKI BOND NO. 12078 to its thread lightly. 99104-31140; SUZUK! BOND NO. 12078 © Fit the gasket and install the oil pan. Tighten the oil bolts to the specified torque. Tightening torque: 12—16 Nem (1.2-1.6 kg-m, 8.5—11.5 lb-ft) NOTE: * Fita new gasket to the oll pen bolt Qeorrectly as shown in the Fig. * Fit the lead wire clamps to the oil pan bolts ®.correctly as shown in the Fig. CAUTION: Use a new gasket to prevent oil leakage. ‘* Tighten the engine oil drain plug to the specified torque. (Refer to page 8-29.) ‘+ Install the countershaft bearing retainer with two screws. NOTE: Apply 2 small quantity of THREAD LOCK “1342"to the two screws. 99000-32050: THREAD LOCK “1342” * Install each gear shifting pawl into the cam shifter. The large shoulder @must face to the outside as shown. ‘* Apply a small quantity of THREAD LOCK “1342” to the screws @ and nut @ . 99000-32050: THREAD LOCK “1342” 09800-09003: Impact driver set + Apply a small quantity of THREAD LOCK SUPER 1303" to the gearshift arm stopper bolt @ and tighten it to the specified torqu 99000-32030: THREAD LOCK SUPER ‘1303”" Tightening torque: 15—23 N-m (1.52.3 kg-m, 11.0—16.5 Ib-ft)MAY-24-2882 16:25 GPO 180302 CERTIFIED Porat ENGINE 3.52 ‘* Install the gearshift shaft return spring, circlip and wash- er onto the gearshift shaft properly. © Install the gearshift shaft and washer. * Fix the gearshift shaft with the circlip. 09900-06107: Snap ring pliers CAUTION: Replace the gearshift shaft oil seal with a new one. + Install the sher @ , pin’@, oll pump driven gear © andwasherr@. * Fix the oil pump driven gear with the circlip. 09900-06107: Snap ring pliers ‘* Install the thrust washer © onto the countershatt. NOTE: Flat surface of washer is positioned outside.MAY-24-2002 16126 GPO 1809082 CERTIFIED P.ee21 3:53 ENGINE ‘© Install the generator/oil pump drive gears @ onto the primary driven gear. « Install the primary driven gear assembly onto the coun- tershaft, and apply engine oil to the needle bearing and spacer. * Install the thrust washer @ onto the countershaft. = Install the clutch sleeve hub onto the countershaft. ‘* Tighten the clutch sleave hub nut to the specified torque by using the torque wrench and clutch sleeve hub holder. 09920-53740: Clutch sleeve hub holder Tightening torque: 80—100 N-m {8.0—10.0 kg-m, 58.0—72.5 lb-ft) ‘+ After tightening the clutch sleeve hub nut, be sure to lock the nut by firmly bending the tongue of lock washer. ‘* Insert the clutch driven plates and drive plates one by one into the clutch sleeve hub in the prescribed order, driven plate first. No.1 and No.2 driven plates can be distinguished by the thickness. Tside No.4 tt): 2.0 am No.2 (i: 1.6 mm No.2 "SpacerMAY-24-2002 16126 GPO 1809082 CERTIFIED ‘© Set the clutch release bearing and washer onto the clutch release rack. '» Put the clutch pressure plate onto the clutch sleeve hub. © Put the clutch spring set bolts onto the clutch pressure plate properly. * Tighten the clutch spring set bolts in the order. NOTE: Tighten the clutch spring set bolts in the manner indicated, tightening them by degrees until they attain @ uniform tightness, Clutch spring set bolt: 11—13 N-m {1.11.3 kg-m, 8.0-9.5 lb-ft) * Coat SUZUKI BOND NO. 12078 lightly to the mating sur- faces @between upper and lower crankeases 8s shown the Fig. 99104-31140: SUZUKI BOND NO. 12078 ‘© Install the dowel pins, a new gasket and clutch cover. ‘© Face the clutch release rack to the rear side so that the clutch release rack and pinion can be engaged easily. * Tighten the cover bolts securely. NOTE: Fit the two gaskets to the clutch cover bolts @correctly as shown in the Fig. CAUTION: Use only new gasket to prevent oil leakagMAY-24-2882 16:26 GPO 180302 CERTIFIED P1021 3-55 ENGINE ‘* Put the signal generator dowel pin @ to the crankcase. * Install the signal generator stator with two screws. ‘* Make sure to fit the slot © on the back surface of the signal generator rator aver the locating pin @ at the end of crankshaft. NOTE: BOND NO. 12078 should be applied to the groove of the signal generator lead wire grommet @ . 99104-31140: SUZUKI BOND NO. 1207B ‘© Hold the crankshaft turning nut and tighten the rotor bolt to the specified torque using 6-mm hexagon wrench. 09900-00410: Hexagon wrench set Tightening torque: 23-26 N-m (2.32.6 ka-m, 16.5—19.0 Ib-ft) ‘ Install the neutral position indicator switch with two screws. NOTE: When installing the neutral position indicator switch, be sure to locate the spring @ , switch contact ® and O-ring @. * Install the oil seal retainer with four bolts, and positively bend the lock portion of the retainer.MAY-24-2002 16127 GPO 1809082 CERTIFIED P.ti2a © Install the water pump with screws and nut. NOTE: * Apply SUZUKI SUPER GREASE ““A”” to the water pump O-ring. + Set the water pump shaft to the oil pump shaft. * When replacing the stud bolt which is located at the po- sition ®, apply SUZUKI BOND NO. 12078 to its threads to prevent oil leakage. 99000-25030: SUZUKI SUPER GREASE “A” 99104-31140: SUZUKI BOND NO. 12078 ‘Water pump 81 pump a 4 o-ring ‘= Install the two dowel pins and C-ring. * Install the starter clutch assembly. Install the starter idle gear and its shaft. Install the shaft end cap to the position @ . Clean the mating surfaces of the upper crankcase and starter clutch cover. Apply SUZUKI BOND NO. 12078 to the mating surface of the starter clutch cover. 99104-31140: SUZUKI BOND NO. 12078 NOTE: Use of SUZUKI BOND NO. 12078 is as follows * Make surfaces free from moisture, oil, dust and other for- eign materials. * Spread on surfaces thinly to form an even layer, and as- semble the cover within few minutes. * Take extreme care not to apply any BOND NO. 12078 to the bearing surfaces. * Apply to cornered surface as it forms @ comparatively thick filma.MAY-24-2002 16127 GPO 1809082 CERTIFIED P.t221 357_ ENGI * Place the starter clutch cover and tighten its bolts to the specified torque. ‘Tightening torque: 8—12 N-m {0.81.2 kg-m, 6.0—8.5 lb-ft) NOTE: * Fit the gaskets to the starter clutch cover bolt @and bolts @)correctly as shown in the Fig. * Fit the oil hose clamp to the starter clutch cover bolt Ocorrectly as shown in the Fig. Bolt @): Copper washer gasket Bolt @: Steel washer with rubber gasket CAUTION: Use a new gasket to prevent oil leakage. * Install the generator with three bolts. Tightening torque: 21—29 N-m (2.12.9 kg-m, 15.0—21.0 Ib-ft) NOTE: Apply SUZUKI SUPER GREASE “A” to the generator O-ring. 99000-25030: SUZUKI SUPER GREASE “A” © Install the starter motor with two bolts. Tightening torque: 4.0—7.0 N-m (0.4—0.7 kg-m, 3,0—5.0 Ib-ft) NOTE: Apply SUZUKI SUPER GREASE “A” to the starter motor O-ring. ‘= Install the piston rings in the order of oil ring, 2nd ring and top ring. NOTE: Top ring and 2nd ring difter in the shape of the ring face. © Top and 2nd rings have a letter ““R" or “AN” marked on the side. Be sure to bring the marked side to the top when fitting them to the piston. é lr WorrnMAY-24-2002 16128 GPO 1809082 CERTIFIED P.13/21 ENGINE 258 * The first member to go into the oil ring groove is a spacer @ . After placing the spacer, fit the two side rails @ Side designations, top and bottom, are not applied to the spacer and side rails: you can position each either way. © Position the gaps of the three rings as shown. Before inserting each piston into the cylinder, check that the gaps are so located. NOTE: When fitting the piston, turn the triangle mark on the pistan head to exhaust side. ‘* Be sure to install the pistons in the eylinder from which ‘they were removed in disassembly, refer to the letter mark, "1" through ‘4’, scribed on the piston. © Have each piston pin moly paste oiled lightly befor stalling it. * Place a cloth beneath the piston, and install the circlips. NOTE: Be sure to use new circles. * Before putting on the cylinder block, oil the big and small ends of each conrod and also the sliding surface of each piston. © Place the new O-rings @ to each cylinder sleeve correct- ly as shown in the Fig. CAUTION: Use @ new O-ring to prevent water leakage.MAY-24-2002 16128 GPO 1809082 CERTIFIED P.1a2n a + Place the dowel pins and new cylinder gasket on the crankcase, CAUTION: Use a new gasket to prevent oil leakage. NOTE: Be sure to identity the top surface by “UP” mark on the eylinder gasket as shown in the Fig. * Install piston ring holders in the indicated manner. Some light resistance must be overcome to lower the cylinder block. ‘* With No.2 and No.3 pistons in place, install No.1 and No.4 pistons, and insert them into the cylinder. 09916-74521: Holder body 09916-74540: Band NOTE: Do not overtighten the special tool bands or the pistons entry into the cylinders will be difficult. * Tighten the cylinder nut @to the specified torque. Tightening torque: 7—11 N-m (0.71.1 kg-m, 5.0—8.0 lb-ft) © Install the cam chain guide @ property. * Place the dowel pins and new cylinder head gasket on the cylinder. CAUTION: Use a new gasket to prevent gas leakage. * Place the cylinder head on the cylinder block. © Tighten the twelve 10-mm bolts to the specified torque with a torque wrench sequentially in the ascending order of numbers. Tightening torque: 40-45 Num (4.04.5 kg-m, 29.0—32.5 Ib-ft) pissMAY-24-2002 16128 GPO 1809082 CERTIFIED P.15/21 ENGINE 3.60 '* After firmly tightening the twelve 10-mm bolts, install one 6-mm bolt @and tighten it to the specified torque. Tightening torque: 8-12 N-m {0,.8—1.2 kg-m, 6.0—8.5 Ib-ft) ‘© While holding down the cam chain, rotate the crankshaft in normal direction to bring the ‘T"’ mark on the rotor to the center of pick-up coil. CAUTION: To turn over crankshaft, torque nut with a 19 mm wrench. Nover try to rotate crankehaft by putting a 6 mm T-type wrench over the bolt. NOTE: Just before placing the camshaft on the cylinder head, ap- ply SUZUKI MOLY PASTE to its journals, fully coating each journal ®) with the paste, taking care not to leave any dry ‘spot. Apply engine oil to the camshaft journal holders. 99000-25140: SUZUKI MOLY PASTE © The exhaust camshaft can be distinguished from that of the intake by the embossed letters “EX” (for exhaust) as against letters ‘IN’ (for intake). Similarly, the right end can be distinguished by the notch © at the right end. * With “"T”’ mark accurately lined up with the timing mark, hold the camshaft steady and lightly pull up the chain to remove the slack between the crank sprocket and exhaust sprocket. © The exhaust sprocket bears an arrow marked “1” indi- cated as @).. Turn over the exhaust camshaft so that the arrow points flush with the gasketed surface of the cylinder head, Engage the cam chain with this sprocket.MAY-24-2002 16129 GPO 1809082 CERTIFIED 2.81_ ENGINE. P.16/21 ‘© The other arrow marked ‘'2"” is now pointing straight up- ward, Count the chain roller pins toward the intake cam- shaft, starting from the roller pin directly above this arrow marked “2” and ending with the 13th roller pin. Engage the cam chain with intake sprocket, locating the 13th pin at the above the arrow marked “3” on the in- ‘take sprocket. NOTE: The cam chain is now riding on all three sprockets. Be careful not to disturb the crankshaft until the camshaft journal holders and cam chain tensioner are secured.MAY-24-2002 16129 GPO 1809082 CERTIFIED P.1721 ENGINE 3.62 ee ee « Each camshaft journal holder is identified with a cast-on letter. Install the dowel pins to each cam- shaft journal holder. * Fasten the camshaft journal holders evenly by tightening the camshaft journal holder bolts se~ quentially in the ascending order of numbers. (Try to equalize the pressure by shifting the wrench in this above manner, to fasten the shafts evenly.) NOTE: Damage to head or camshaft journal holder thrust surfaces may result if the camshaft journal holders are not drawn down evenly. ‘¢ Tighten the camshaft journal holder bolts to the specified torque. Tightening torque: 8—12 Nm (0.8—1.2 kg-m, 6.0—8.5 Ib-ft) CAUTION: ‘The camshaft journal holder bolts are made of a special material and much superior in strength, com- pared with other types of high strength bolts. ‘Take special care not to use other types of bolts instead of these special bolts. To identify these bolts, each of them has a figure “9” on its head.MAY-24-2002 16129 GPO 1809082 CERTIFIED P.18/21 363 ENGINE * After removing the spring holder bolt @ and spring, un- lock the ratchet mechanism @ and push in the push rod @ all the way. NOTE: Before installing the cam chain tensioner, turn the crank- o shaft clockwise to remove the cam chain slack between the crank sprocket and exhaust sprocket. *» Install a new gasket and the cam chain tensioner. to the eylinder block with two bolts and tighten them to the specified torque. Tightening torque: 6—8 Nem (0.6—0.8 kg-m, 4.5—6.0 Ib-ft) * Insert the spring into the cam chain tensioner and tight- en the spring holder bolt @) to the specified torque. Tightening torque: 30—45 N-m {3.0—4.5 kg-m, 21.5—32.5 lb-ft) CAUTION: After installing the cam chain tensioner, check to be sure that the tensioner work properly by checking the siack of cam chain. * Pour about 50 mi of engine oil in each oil pocket in the head. NOTE: Turn the crankshaft and check that all the moving parts such as cam follower, camshaft, work properly. CAUTION: Be sure to check the tappet clearance. (Rafer to page 2-4.) * Place the oil pipes @ to the camshaft journal holders as shown in the Fig. NOTE: Be sure to bring the white painted side @on the oil pipes to the top when installing them to the camshaft journal holders. Tightening torque: 8—12 N-m (0.8—1.2 kg-m, 6.0—8.5 lb-ft)MAY-24-2002 16138 GPO 1809082 CERTIFIED P1972. * Coat SUZUKI BOND NO. 12078 lightly to the mating st faces between upper and lower crankoases as shown in the Fig. 99104-31140: SUZUKI BOND NO. 12078 ‘+ Install a new gasket and the signal generator cover with five bolts. NOTE: Fit a gasket to the signal generator cover bolt @)correctly as shown in the Fig. CAUTION: Use a new gasket to prevent oil leakage. * Place the left and right oil hoses as shown in the Fig. NOTE: * Install the new gaskets to both sides of the union bolt. * Be sure to bring the green painted side @ on the oil hoses to the top when installing them. Refer to page 8-17. CAUTION: Replace the gaskets with new ones to prevent oil leakage. ‘Tightening torque Upper side @): 2023 N-m (2.0—2.3 kg-m, 14.5—16.6 Ib-ft) Lower side @; 25—29 N-m {2.5—2.9 kgm, 18.0—21.0 lb-ft) ‘* Before installing the cylinder head cover gaskets on the cylinder head cover, apply SUZUKI BOND NO. 12078 to the grooves of the head cover. ‘¢ Apply SUZUKI BOND NO. 12078 to the four cam end caps of the gasket and shown in the Fig. 99104-31140; SUZUKI BOND NO. 12078MAY-24-2002 16138 GPO 1809082 CERTIFIED 305 ENGINE P.2e21 S85 ENG ‘* Place the cylinder head cover on the cylinder head. « Fit the eight gaskets to cach head cover bolt. NOTE: Be sure to face the arrow mark on the cylinder head cover to the front side. CAUTION: Replace the gaskets with new ones to prevent oll leakage. Tightening torque Head cover bolt: 13—15 N-m (1.3-1.5 kg-m, 9.5—11.0 lb-ft) = Fit the new O-rings @ to the inlet and outlet water pipes. NOTE: Before installing the water pipes.to the cylinder block, ap- ply engine oil lightly to each O-ring. * Install the inlet and outlet water pipes to the cylinder block, NOTE: When installing the inlet water pipe @ to the cylinder block, apply @ small quantity of the SUZUKI BOND NO. 12078 to the inlet water pipe mounting bolts ®. 99104-31140: SUZUKI BOND NO. 12078 * Tighten the water pipe mounting bolts to the specified torque. Tightening torque: 8—12 N- {0.8—1.2 kg-m, 6.0—8.5 lb-ft) “FRONT” Ss 1 qMAY-24-2002 16138 GPO 1809082 CERTIFIED P.21/21 ENGINE 3.65 NOTE: When replacing the intake pipes, identify the different intake pipes according to each 1.D. code. (13110-2100 for No.1 cylinder) (131 10-21E00 for No.2 cylinder) (13120-21E00 for No.3 cylinder) {13120-2100 for No.4 cylinder) No.3, CAUTION: Use a new O-ring to prevent sucking air from the joint. © Install the oil cooler and tighten its mounting bolt to the specified torque. NOTE: * Before installing the oil cooler, apply engine ail lightly to its O-ring. * Set the lug © of the oil cooler to the recess of the crankcase. Tightening torque: 53—-64 N-m {6.3-6.4 kg-m, 38.5—46.5 lb-ft) ‘* Install the oil filter turning it by hand until you feel that the filter gasket contacts the mounting surface. Then tighten it 2 turns by using the special tool. (09915-40610: Oi filter wronch NOTE: Before installing the oil filter, apply engine oil lightly to its O-ring. TOTAL P.21MAY-24-2002 17:27 GPO 1809082 CERTIFIED P.a122 FUEL AND LUBRICATION SYSTEM FUEL SYSIEM - FUEL PUMP --- FUEL PUMP REMOVAL FUEL PUMP INSPECTION « FUEL COCK -- FUEL COCK REMOVAL FUEL TANK AND FUEL FILTER FUEL TANK REMOVAL - FUEL FILTER REMOVAL INSPECTION AND CLEANING - CARBURETOR ~~ CONSTRUCTION - SPECIFICATIONS - 1.D. NO. LOCATION DIAPHRAGM AND PISTON OPERATION SLOW SYSTEM MAIN SYSTEM STARTER SYSTEM - FLOAT SYSTEM REMOVAL -- DISASSEMBLY - INSPECTION AND ADJUSTMENT NEEDLE VALVE INSPECTION --- FLOAT HEIGHT ADJUSTMENT ~ REASSEMBLY AND REMOUNTING BALANCE OF CARBURETORS -- LUBRICATION SYSTEM OIL PRESSURE Ol FLTER OIL SUMP FILTER ENGINE LUBRICATION SYSTEM CHART ENGINE LUBRICATION SYSTEM ENGINE Ol. COOLING SYSTEM WONVNVABHAADAAALWNSMAY-24-2002 17:27 GPO 1809082 CERTIFIED P.@222 41_FUEL AND LUBRICATION SYSTEM 4&1 FUEL AND LUBRICATION SYSTEM FUEL SYSTEM ‘The fuel pump is operated by an electro-magnetic force and its electrical energy is supplied from the battery which is controlled by the fuel pump relay’s control circuit. The fuel sent under pressure by the fuel pump flows into the float chamber when the float of the carburetor has dropped and the needle valve is open. When the needle valve closes, the pressure of the fuel in the hose connect- ing the carburetor and the fuel pump increases, and when the set pressure is reached, the operation of the fuel pump is stopped by the fuel pressure to prevent excessive supply. CerburetorMAY-24-2002 1 GPO 1S09082 CERTIFIED P.e3/22 FUEL AND LUBRICATION SYSTEM i EE FUEL PUMP DESCRIPTION Starting Engine: In order to supplement fuel supply when starting the engine by turning the starter switch ON, cur- rent @ is sent directly from the battery and passes through the fuel pump relay, thus operating the fuel pump. After start: The current @ generated at coils No.2/No.3 flows to the fuel pump relay’s control circuit. The con- trol circuit receives this current @) and sends signal @ to the SCR, turning it ON. When the SCR tums ON, current @ is sent from the battery through the fuel pump relay, thus operating the fuel pump. #2/#3 Ignition coil “Tl 10 side-stand switch WIRE COLOR B/W : Black with White acer YIG + Yellow with Green tracer B/Y : Black with Yollow tracer = __O/W: Orange with White tracerMAY-24-2002 17:28 GPO 1809082 CERTIFIED P.04722 43 FUEL AND LUBRICATION SYSTEM FUEL PUMP REMOVAL ‘+ Remove the seats. (Refer to page 7-5.) ‘= Remove the frame cover assembly. ‘+ Tum the fuel cock ““OFF” position and disconnect the fuel hoses (D and @) from the fuel pump. * Disconnect the fuel pump lead wire coupler and remove the fuel pump mounting bolts. @: Outlet hose @; Inlet hose FUEL PUMP INSPECTION © Using the pocket tester (x k@ range), measure the resistance between the lead wires in the following table. If the resistance checked is incorrect, replace the fuel pump. 09900-25002: Pocket tester NOTE: As capacitor, diodes, etc. are used inside this fuel pump, the resistance values will differ when an ohmmeter other than SUZUKI pocket tester is used. (Approx. kQ) coer @ Probe of tester to: O/W: Orange with White tracer 3s B/Y : Black with Yellow tracer 2 ow BY YIG Bw 3 |_ow ec [an ° ey = 3 viG co 45-55 10-12 @O| aw «© | 31-37 | 10-12 vig BwMAY-24-2002 1741 GPO 1809082 CERTIFIED FUEL COCK FUEL COCK MECHANISM ‘A valve is provided at the end of the fuel cock lever and can switch over to “OFF”, ““ON’’ and “RES”. With the valve “ON” (normal), the main passage opens. With the valve “OFF”, both holes close. FUEL COCK REMOVAL * Remove the seats and frame cover assembly. (Refer to page 7-5.) * Remove the fuel cock mounting screws. * Bend the fuel hoses with a soft clip and disconnect the fuel hoses from the fuel cock. WARNING: Gasoline is very explosive. Extreme care must be taken. aeMAY-24-2002 17:28 GPO 1809082 CERTIFIED P.26722 45 FUEL AND LUBRICATION SYSTEM, FUEL TANK AND FUEL FILTER FUEL TANK REMOVAL + Remove the seats and frame cover assembly. (Refer to page 7-5.) = Turn the fuel cock to ““OFF"” position and disconnect the fuel cock outlet hose @. * Disconnect the fuel level indicator switeh lead wire cou- pler @. ‘+ Remove the fuel cock mounting screws. ‘= Remove the fuel tank by removing the mounting botts. WARNING: Gasoline is very explosive. Extreme care must be taken. FUEL FILTER REMOVAL ‘* Remove the fuel filter assembly by removing the bolts. WARNING: Gasoline is very explosive. Extreme care must be taken. Gaskets and O-ring must be replaced with new ones to pre- vent fuel leakage. INSPECTION AND CLEANING 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.MAY-24-2002 17:29 GPO 1809082 CERTIFIED P.ar22 FUEL AND LUBRICATION SYSTEM 4-6 CARBURETOR CONSTRUCTION Throttle valve balance screw Fuel hose connector set Air vent hose connector Q Top cap Fist valve guide @ Mixing Doty Air veet hoas Spring Needle jet Noodle jet sot bott Diaphragm chamber hose Spring seat Needle valve ass'y set serew connector Exing’ Needle valve ass’y Spacer Washer Float Carburetor set upper shaft Jet needle Gasket Carburetor set lower shaft Diaphragm Drain eorew Starter shaft lever © Piston @ Pilot screw ‘Throttle stop screwMAY-24-2882 17:89 4-7_FUEL AND LUBRICATION SYSTEM. GPO 180302 CERTIFIED P.e822 SPECIFICATIONS SPECIFICATION oe £03, USA. £33, U.S.A. (Calif. model) Carburetor type MIKUNI BDSTSESS MIKUNT BDSTIISS Bore size 36 mm 33 mm LD. No. 2164 2165 Idle r/min. 1. 300* 100 r/min 1350+ 100 r/min Float height, 6.9% 1.0 mm (0.2720,04 in) = Main jet (M.J.) Hes #107.5 Main air jet (M.A.J.) 0.6 mm aad Jet needle {J.N.) S5EQ7 SES Needle jet IN.) o-5 o-8 Throttle vaive (Th.V.) #120 aed Pilot jet {P.J.) ets #10 (G.5.) #47.5 = (P.S.) PRE-SET _ ‘Starter jet Pilot screw Throttle cable play (0.51.0 mm (0,02—0,04 in) 1.D. NO. LOCATION Each carburetor has |.D. Number @ printed on the carbure- tor body according to its specification.MAY-24-2002 17:29 GPO 1809082 CERTIFIED P.es22 FUEL AND LUBRICATION SYSTEM 4.8 DIAPHRAGM AND PISTON OPERATION ‘The carburetor is a variable-venturi type, whose venturi cross section area is increased or decreased automatically by the piston valve @ which moves according to the negative pressure present on the downstream side of the venturi @). Negative pressure is admitted into the diaphragm chamber @ through two orifices © provided in the piston valve © - Rising negative pressure overcomes the spring @ force, causing the piston vaive @ to rise to in- crease the said area and thus prevent the air velocity from increasing. Thus, air velocity in the ventu- Fi passage is kept relatively constant for improved fuel atomization and for securing optimum ratio of fuel/air mixture. LOWER POSITION OF PISTON VALVE UPPER POSITION OF PISTON VALVE amin crv pressure Gem veccative pressure ee odMAY-24-2002 17118 GPO 1809082 CERTIFIED P.11722 FUEL AND LUBRICATION SYSTEM_410 MAIN SYSTEM ‘As throttle valve @ is opened, engine speed rises, and this increases negative pressure in the venti 1i@. Consequently the piston valve @ moves upward. Meanwhile, the fuel in float chamber @) is metered by main jet @ , and the metered fuel enters nee dle jet © , in which it mixes with the air admitted through main air jet © to form an emulsion. The emulsified fuel then passes through the clearance between needle jet © and jet needle @ , and is discharged inta the venturi @, in which it meets main air stream being drawn by the engine. Mixture proportioning is accomplished in needle jet ©); the clearance through which the emulsified fuel must flow in large or small, depending ultimately on throttle position. FUEL GE uv 4in wocruneMAY-24-2002 17118 GPO 1809082 CERTIFIED P. 12722 4X11 FUEL AND LUBRICATION SYSTEM STARTER SYSTEM Pulling up the starter shaft @ , fuel is drawn into the starter circuit from the float chamber @) - Starter jet @ meters this fuel, which then flows into starter pipe @ and mixes with the air coming from the float chamber @ . The mixture, rich in fuel content, reaches starter plunger ©) and mixes again with the eir coming through a passage extending from behind the diaphragm. The two successive mixings of fuel with air are such that proper fuel/air mixture for starting is produced when the mixture is sprayed out through starter outlet © into the main bore. ar > FUEL/AIR MIXTURE > ae FLOAT SYSTEM Floats @ and needle valve @ are associated with the same mechanism, so that, as the floats @ move up and down, the needle valve @ too moves likewise. When fuel level is up in float chamber @, floats @ are up and needle vaive @ remains pushed up against vaive seat. Under this condition, no fuel enters the float chamber @ « As the fuel level falls, floats @) go down and needle valve @ unseats itself to admit fuel into the chamber @) . In this manner, needle vaive @ admits and shuts off fuel alternately to maintain a practically constant fuel level in- side the float chamber © . 7 reMAY-24-2002 17911 GPO 1809082 CERTIFIED P.13/22 FUEL AND LUBRICATION SYSTEM 4.12 REMOVAL Refer to page 3-3. DISASSEMBLY * Remove the throttle cables from the throttle lever. * Disconnect the air vent hoses @ and diaphragm cham- ber air cleaner hoses @ . ‘© Remove the starter shaft lever @ . ‘* Remove the upper and lower carburetor set shafts. '* Separate the carburetor assembly.MAY-24-2002 17911 GPO 1809082 CERTIFIED P.14722 4.13. FUEL AND LUBRICATION SYSTEM ‘+ Remove the carburetor top cap @ - ‘+ Remove the piston valve return spring @ and piston valve with diaphragm @ « * Remove the O-ring @ . ‘+ Remove the float chamber body © - 09900-09003: Impact driver set = '* Remove the float assembly © . ‘+ Remove the starter plunger assembly @ .MAY-24-2082 17311 GPO 180302 CERTIFIED P.1522 EUEL AND LUBRICATION SYSTEM 4.16 © Remove the main jet © , pilot jot @ and starter jet © - CAUTION: Do not remove the pilot screw @), This component is PRE- SET at the factory by the very specialized equipment. ‘* Remove two throttle valve screws © and pull out throt- tle valve plate. CAUTION: ‘These two screws are locked by punching these ends. Once removing the scraws, they will be damaged. NOTE: Wher reinstalling the throttle valve plate, apply a small quan- tity of the THREAD LOCK “1342” to its screws ©. 99000-32050: THREAD LOCK ‘1342’ ‘* Remove the jet needle © from the piston valve @ . * Remove the mixing body by removing the bolt @ . ‘= Remove the carb. diaphragm chamber air cleaner element.MAY-24-2002 17911 GPO 1809082 CERTIFIED P.16/722 4.15 FUEL AND LUBRICATION SYSTEM Cleaning of Carb. diaphragm chamber air cleaner clement ‘© Immerse the element in the cleaning solvent and wash it cl ‘© Squeeze the cleaning solvent out of the washed element by pressing it between the palms of both hands. ‘= Immerse the element in motor oil, and squeeze the oil out of the element leaving it slightly wet with oll. INSPECTION AND ADJUSTMENT Check following items for any damage or clogging. * Pilot jet * Needle valve * Main jet * Starter jet + Main air jet * Gasket and O-ring + Pilot air jet * Throttle shaft oil + Needle jet air bleeding hole * Diaphragm * Float * Pilot outlet and by-pass holes NEEDLE VALVE INSPECTION If foreign matter is caught between the valve seat and the needle, the gasoline will continue flowing and cause it to ; overflow. If the seat and needle are wor beyond the per- missible limits, similar trouble will occur. Conversely, if the needle sticks, the gasoline will not flow into the float cl ber. Clean tha float chamber and float oarts with aasoline. FLOAT HEIGHT ADJUSTMENT To check the float height, invert the carburetor body, with the float arm kept free, measure the height @ while float arm is just in contact with needle valve by using calipers. Bend the tongue @ as necessary to bring the height @ to this value. Float height @: 6.91.0 mm (0.27:0.04 in) 09900-20102: Vernier calipers REASSEMBLY AND REMOUNTING Reassemble and remount the carburetor assembly in the reverse order of disassembly and removal. Pay attention to the following points: * When engaging two carburetors, position the throttle valve control lever @ correctly.MAY-24-2002 17112 GPO 1809082 CERTIFIED * Set each throttle valve in such a way that its top end @ meets the foremost by-pass @) . This is accomplished by ‘turning the throttle stop screw and throttle valve balance screw. ‘© After all wok is completed, mount the carburetors on the engine and the following adjustments are necessary. * Engine idle r/min * Throttle cable play... * Balancing carburetors BALANCE OF CARBURETORS Check the four carburetors for balancing movement accord- ing to the following procedures. NOTE: When balancing the carburetors, remove the fuel tank and fuel should be supplied by # separate fuel tank @). CALIBRATING EACH GAUGE ‘* Start up the engine and run it in idling condition for warm- ing up. ‘© Stop the warmed-up engine. ‘* Remove the vacuum inlet cap @ for No.1 or No.4 cylinder. * Connect one of the four rubber hoses of balancer gauge to this inlet. 09913-13121: Carburetor balancer FUEL AND, THON SYSTEM. 41 P.17722 @ ®MAY-24-2002 17112 GPO 1809082 CERTIFIED 4:17_ FUEL AND LUBRICATION SYSTEM P.18/722 * Start up the engine and keep it running at 1.750 r/min by turning throttle stop screw. ‘* Turn the air screw @ of the gauge so that the vacuum acting on the tube of that hose will bring the steel ball @ in the tube to the center line @ . ‘* After making sure that the steel ball stays steady at the center line, disconnect the hose from inlet and connect the next hose to the inlet. ‘* Tum air screw to bring the other stee! ball @ to the center line. ‘+ Repeat the above process on the third and fourth hoses. The balancer gauge is now ready for use in balancing the carburetors. BALANCING CARBURETORS ining all the carburetor movement, remove all the let caps from each carburetor. Connect the balancer gauge hoses to these vacuum inlets and adjust the balance of four carburetors as follows: * Start up the engine and keep it running at 1750 r/min to see engine tachometer reading.GPO 1809082 CERTIFIED A correctly adjusted carburetor has the steel balls in the Nos. 1 through 4 tubes at the same level, ‘If the steel balls are not in correct positions, adjust the throttle valve balance screws correctly. © Adjusting order is as follows. t ® 4 © '* After balancing the carburetors, set there speed between 1200 and 1400 r/min, by turning the throttle stop screw referring engine tachometer reading. Idle r/min: 1300+ 100 r/min ... E-03 Idle rimin: 1350+ 100 r/min CAUTION: Do net disturb the pilat screw. This component is PRE-SET at the factory by tho very specialized equipment. LUBRICATION SYSTEM OIL PRESSURE Refer to page 2-22. OIL FILTER Reter to page 2-9, OIL SUMP FILTER When you wash the oil pan, check to be sure that the oil sump filter is free from any sign of rupture, also wash the filter clean periodically. CAUTION: Replace the oil pan gasket with a new one to pravent oil leakage. (Refer to pages 3-50 and 3-61.) P.19722 FUEL AND LUBRIGATION SYSTEM. 4,P.20722 GPO 1809082 CERTIFIED MAY-24-2002 17113 419 FUEL AND LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM CHART Ge ew & wy OG ia) J ee NS OS y veer wee vee ¥ ” Ur ts é WSL ans 10 ' ’ ’ | ane ste oxy ens gi ae anne We evneanwa Lwusuainnio3 idol t 1 ee ‘OMaNaG ‘oMuWaa HOLS w100 10 : 00S M9 ais1a31 ' gunssaua wo aa sees AWNSULANNOS § see ‘ony Suva t — GaLyaH SUI GY wn Wo aug wuwvis j<—] iar 0 Be 10 ¥ S80 10 ¥, AYITIVD NIVW — van BIONTTAD = Sava ‘ony SivRANOr Siva wv ‘ony Stywanor| LAYHSINVD DALAL .avHSWNYD LSMVINX) wid woisia anv || oust any moisid ON || NOLSid EON ‘ila wousta ONY woisia ZOMAY-24-2002 17113 GPO 1809082 CERTIFIED P.2iv22 FUEL AND LUBRICATION SYSTEM 4.20 ENGINE LUBRICATION SYSTEMMAY-24-2002 17514 GPO 1809082 CERTIFIED P.22722 4.21_ FUEL AND LUBRICATION SYSTEM ENGINE OIL COOLING SYSTEM <5 water Low <} onrow ( TOTAL P.22MAY-25-2082 81:@7P FROM: TO: 18478730197 Pri715, COOLING SYSTEM CONTENTS: COOLING SYSTEM DESCRIPTION CONSTRUCTION COOLING SOLUTION COOLING SYSTEM REMOVAL AND DISASSEMBLY WATER HOSES AND THERMOSTAT CASE RADIATOR COOLING FAN ENGINE COOLANT TEMPERATURE GAUGE AND COOLING FAN THERMO-SWITCH - THERMOSTAT + WATER PUMP - RADIATOR INSPECTION « REMOVAL INSTALLATION ENGINE COOLANT TEMPERATURE GAUGE REMOVAL INSPECTION REASSEMBLY COOLING FAN REMOVAL INSPECTION COOLING FAN THERMO-SWITCH REMOVAL INSPECTION REASSEMBLY THERMOSTAT REMOVAL INSPECTION REASSEMBLY WATER PUMP --- REMOVAL AND DISASSEMBLY INSPECTION REASSEMBLY ~~ | SOCHRHHHRAR OAAGDANASMAY-25-2082 81:@7P FROM: TO: 18478730197 5.1 COOLING SYSTEM 5.1 COOLING SYSTEM COOLING SYSTEM DESCRIPTION The engine is cooled by engine cooiant set in forced recirculation through jackets formed in the cylinder and cylinder head, and through the radiator. For the water pump, a high-capacity centrifugal pump Is used. The radiator is a tube-and-fin type made of aluminum material, which Is characterized by lightness in weight and good heat dissipation. ‘The thermostat is of wax pellet type, complete with a valve as the means of temperature-dependent control ever the flow of engine coolant through the radiator. The valve is actuated by the temperature- sensitive wax contained in the pellet. Referring to the following illustration, the thermostat is in the closed condition, so that engine coolant recirculates through the route comprising pump, engine, by-pass hole of the thermostat and radiator in the regulated condition. As the engine coolant temperature rises to 76.5°C and the thermostat valve unseats, the normal engine coolant flow is established. At about 90°C of engine coolant temperature, the thermostat becomes completely open and most of heat is released to the atmosphere through the radiator core. 15 CcMAY-25-2082 81:@7P FROM: TO: 18478730197 P15, COOLING SYSTEM 5-2 CONSTRUCTION Tightening torque eM | Nem ka-m Theft jae] s—12 | 08-12 | 60-85 ©O | ss-s [0.66—0.8 | 4.0-6.0 @ Radiator @ Radiator cap © Engine coolant reservoirMAY-25-2082 81:@8P FROM: TO: 18478730197 5.3 COOLING SYSTEM Tightening torque em | _Wim bk eS! 4_ 6. © 4-7 3.0-5.0 OG 8-12 6.0-8.5 © 7-9 . - © shroud @ Fan motor & Cooling tan © Radiator ® ® oW seat © Stuffing box Ch ® O-ring eo ® Bearing © Bearing chanical @ Cirelip i Tightening Torque Tem | Nem kom © | 7-11 [a7 © 79 | 0.7—0.9MAY-25-2082 81:@8P FROM: TO: 18478730197 5715 COOLING SYSTEM 5.4 COOLING SOLUTION Water [1225 mi(1.a/1.1 USiimp. av) ian PO LEROIRE, |1228 mt [At the time of manufacture, the cooling system is filled with 3 50 ; 50 solution of distilled water and anti-freeze/summer coolant. This 60 : 50 mixture will provide excellent heat pro- tection, and will protect the cooling system from freezing ce . at temperatures above —31°C (—24°F), ae aa ate If the motorcycle is to be exposed to temperatures below —31°C (—24°F}, this mixing ratio should be increased up 7**)"*0 18 g to 55% oF 60% according to the Fig. 2. 5 xefr20 oo @ NOTE: 2 mlu0 os The charactoristics of different anti-freezes vary. Read the 20/110 og label to know the protection you will have. rato bet CAUTION: e Do not put in more than 60% anti-freeze or less than 50%. Do not mix differant brands of anti-freeze. Fig. 1 Engine a eo Ryo 2 +}20 B a2}20 Z 0) £ se] 20 70} 0 1 .2| 70 vi 20106088 Densty om) Fig. 2 Engine coolant density-freezing point curve.MAY-25-2082 81:@8P FROM: TO: 18478730197 P6715, 5.5 COOLING SYSTEM COOLING SYSTEM REMOVAL AND DISASSEMBLY WATER HOSES AND THERMOSTAT CASE * Remove the lower cowling. (Refer to page 7-2.) ‘* Remove the gearshift lever and engine sprocket cover. (Refer to page 3-6.) ‘* Drain out engine coolant by removing the water hose © ‘+ Remove the thermostat case bracket mounting bolts. * Loosen the clamp screws and disconnect water hoses. ‘* Disconnect the engine coolant temperature gauge lead wire, cooling fan switch lead wire coupler and ground wire. ‘+ Remove the thermostat case along with the water hoses. RADIATOR ‘* Remove the radiator by removing the mounting bots.MAY-25-2082 81:@9P FROM: COOLING FAN ‘* Remove the cooling fan. ENGINE COOLANT TEMPERATURE GAUGE AND COOLING FAN THERMO-SWITCH * Loosen the clamp screw and disconnect the water hose. + Remove the water temperature gauge @ and cooling fan thermo-switch @ « THERMOSTAT @ Separate the thermostat case into halves and remove the thermostat. WATER PUMP ‘* Remove the gearshift lever and engine sprocket cover. (Refer to page 3-6.) © Remove the water pump assembly. * Remove the water pump cover. TO: 18478730197 P7715, COOLING SYSTEM 5-6MAY-25-2082 81:@9P FROM: TO: 18478730197 P8715, 5:7 COOLING SYSTEM + Remove the impeller securing bolt by holding the impeller shaft with a water pump pliers. '* Remove the mechanical seal ring. ‘= Remove the circlip from the impeller shaft. ‘+ Remove the impelier shaft. ‘* Remove the mechanical seal. ‘* Remove the oil seal. CAUTION: ‘The removed mechanical seal or oil seal should be replaced with a new one. * Drive out the bearings by using a suitable bar. ( CAUTION: ‘The ramoved bearings should be replaced with new ones. Refer to page 6-13 for INSPECTION AND REASSEMBLY.TO: 18478730197 COOLING SYSTEM ees eee RADIATOR INSPECTION Before removing the radiator and draining the engine coolant, inspect the following items. +1. Test the cooling system for tightness by using the radia- tor tester as follows: Remove the radiator cap, and con- nect the tester to the filler. Give a pressure of about 1.2 kg/em? (17 poi, 120 kPa) and see if the system holds this pressure for 10 seconds. If the pressure should fall dur- ing this 10-second interval, it means that there is a leak- ing point in the system. In such @ case, inspect the entire system and replace the leaking component or part. 2, Test the radiator cap for relieving pressure by using the radiator tester in the following manner: Fit the cap to the tester, as shown, and build up pressure slowly by oper- ating the tester, Make sure that the pressure build-up stops at 1.10.15 kg/em? (15.6 2.1 psi, 110 16 kPa) and thet, with the tester held standstill. he cap is capa~ ble of that pressure for at least 10 seconds. Replace the cap if it is found not to satisfy either of these two re- quirements. Radiator cap valve release prossure: 1.1:40.15 kg/cm? (18.6+ 2.1 psi, 110+ 15 kPa) 3. Road dirt or trash stuck to the fins must be removed. Use of compressed air is recommended for this cleaning. Fins bent down or dented can be repaired by straightening them with the blade of a small screwdriver. 4, Any water hose found in a cracked condition or flattened must be replaced, Any leakage from the connecting sec tion should be corrected by proper tightening. ~ REMOVAL © Refer to page 5-5. INSTALLATION The radiator is to be installed in the reverse order of the removal procedure. After installing the radiator, be sure to add engine coolant: refer to page 2-13 for refilling infor- mation.MAY-25-2082 81: 10P FROM: TO: 18478730197 59 COOLING SYSTEM P1015 ENGINE COOLANT TEMPERATURE GAUGE ‘The following circuit diagram shows the electrical wiring for the thermometer, The major compo- nents are temperature gauge in contact with engine coolant; and temperature indicator (engine coolant temperature meter). IG. switen Engine coolant temperature meter erer WIRE COLOR "Red Orange hangs win Gren va 2 Bick with Grown tracer De Black with Brown tracer REMOVAL - * Refer to page 5-6. INSPECTION Test the temperature gauge at the bench to see if its ohmic value changes, as specified, with temperature. The test is to be run as follows: Connect the temperature gauge to the ‘ohmmeter and place it in the oil contained in a pan, which is placed on a stove; heat the oil to raise its temperature slowly, reading the thermometer pleced in the pan and also the ohmmeter. A temperature gauge whose ohmic value does not change in the proportion indicated in the table must be replaced. 09900-25002: Pocket tester ‘Temperature gauge specification Engine coolant temperature| Standard resistance 50°C (122°F) ‘Approx. 153.9 @ BOSC (176°F) Approx. 51.99 100°C (212°F) ‘Approx. 27.49 120°C (248°F) Approx. 16.1 2 If the resistence noted to show infinity or too much differ- ent resistance value, temperature gauge must be replaced. For inspecting the engine coolant temperature meter, refer to page 6-24.COOLING SYSTEM 5.10 REASSEMBLY Apply SUZUKI BOND NO. 12078 to the thread portion of the ‘temperature gauge and tighten it to the specified torque. 99104-31140; SUZUKI BOND NO.1207B Tightening torque Engine coolant temperature gauge: 6.0—9.0 Nem {0.6—0.9 kg-m. 4.5—6.5 Ib-ft) CAUTION: Take special care when handling the temperature gauge. If may cause damage if it gets a sharp impact. ‘+ Fill the specified engine coolant. (Refer to page 2-13.) COOLING FAN REMOVAL « Refer to page 5-6. INSPECTION Test the cooling fan drive motor for load current with an am- meter connected as shown in the illustration. The voltmeter is for making sure that the battery applies 12 pee rere volts to the moter. With the motor with electric motor fan running at full speed, the ammeter should be indicating not Hl more than 5 amperes. - If the fan motor does not turn, replace the motor assembly with © new one. Bartery COOLING FAN THERMO-SWITCH ‘The cooling fen, being located behind the radiator, is secured to the radiator by three bolts. The fan drive motor is automatically controlled by the thermo-switch. This switch remains open when the ‘temperature of engine coolant is low, but it closes at about 105°C (221 °F) of rising engine coolant ‘temperature to set the fan in motion. 1G. switch Fuse fuse Fan motor Thormo- ‘switch Laid WIRE COLOR ZL BYR 3 Black with Red tracer 2 BIW: Black with White tracorMAY-25-2082 81: 10P FROM: TO: 18478730197 §11_ COOLING SYSTEM REMOVAL © Refer to page 5-6. INSPECTION ‘+ The thermo-switch must be checked for its temperature- initiated closing action at the specification value of 105°C (21°F) by testing it at the bench as shown in the figure. Connect the thermo-switch to a circuit tester and place It in the oil contained in a pan, which is placed on a stove; heat the oll to raise its temperature slowly, and read the column thermometer when the switch closes. 09900-25002: Pocket tester Thermo-switch specification OFF — ON ‘Approx. 105°C (221°F) ‘ON — OFF ‘Approx. 100°C (212°F) REASSEMBLY NOTE: Do not forget the new O-ring. Tightening torque Thermo-switch: 9.0—14 N-m {0.9—1.4 kg-m, 6.8—10.0 tb-ft) CAUTION: ‘Take special care when handling the thermo-switch. It may cause damage if it gets a sharp impact. Replace the O-ring with a new one.MAY-25-2082 81: 10P FROM: TO: 18478730197 P:1315 COOLING SYSTEM 6-12 THERMOSTAT REMOVAL + Refer to page 5-6. INSPECTION Inspect the thermostat pellet for signs of cracking. Test the thermostat at the bench for control action, in the following manner. ‘* Passa string between flange, as shown in the illustration. ‘* Immerse the thermostat in the water contained in a beak- er, as shown in the illustration. Note that the immersed thermostat is in suspension, Heat the water by placing the beaker on a stove and observe the rising temperature ‘on a thermometer. ‘= Read the thermometer just when opening the thermostat. This reading, which is the temperature level at which the thermostat valve begins to open, should be anywhere be- tween 74.5°C (166.1°F) and 78.5°C (173,3°F). ‘Thermostat valve opening temperature: 74.5—78.5°C (166.1—173.3°F) = Keep on heating the water to raise its temperature to and beyond 80°C (194°F). '* Just when the water reaches 90°C (194°F}, the ther- mostat valve should have lifted by at least 7.0 mm (0.28 in). Thermostat valve lift: Over 7.0 mm at 90°C {Over 0.28 In at 194°F) = A thermostat failing to satisfy either of the two require- ments (start-to-open temperature and valve lift) must be replaced. REASSEMBLY ‘© The air bleeder hole @ of the thermostat faces upside. ‘* Replace the O-ring with a new one.MAY-25-2082 @1:11P FROM: TO: 18478730197 P1415 3 COOLING SYSTEM WATER PUMP REMOVAL AND DISASSEMBLY Refer to page 5-6 for the water pump removal and disas- sembly procedures. INSPECTION WATER PUMP BEARING ‘Turn the inner race and check the bearing play. If abnormal noise occurs or eny sign of stickiness is noted, replace the bearing with a new one. MECHANICAL SEAL Visually inspect the mechanical seal for damage, with par- ticular attention given to the sealing face. Replace the mechar that shows indications of leakage. Also replace the oil seal if necessary. REASSEMBLY 7 Reassemble and remount the water pump in the reverse ord- #r of removal and disassembly. Pay attention to the follow- ing points: * Press the new bearings into the stuffing box with the spe- cial tool and a suitable size sleeve etc. 09924-84521: Bearing Installer © Apply grease to the oil seal lip before installing. 99000-25030; SUZUKI SUPER GREASE “A” * Press the new oil seal into the stuffing box with the spe- cial tool and a suitable size sleeve etc. 09924-84521: Bearing installer Press the new mechanical seal into the stuffing box with the special tool and a suitable size sleeve etc. NOTE: When installing the mechanical seal, apply SUZUKI BOND NO.12078 to its outer surface. 99104-31140: SUZUKI BOND NO.12078 es ,MAY-25-2082 @1:11P FROM: TO: 18478730197 15715, COOLING SYSTEM 5.14 ‘+ Replace the O-rings and water seal with new ones when reassembling the water pump. NOTE: The mechanical seal ring must be assembled with marked face @ of the ring toward the impeller. © Tightening the impelier securing bolt to the specified torque. Tightening torque: 7—9 N-m : (0.7—0.9 kg-m, 5.0—6.5 Ib-ft) - NOTE: The seal lip side @) faces impeller. Water pump 01 pump Before instaling the mechanical seal, Mechanical seal BOND NO.12078 to Its outer surface. Refer to page 8-18 for the radiator hose routing.MAY-25-2082 81:35P FROM: TO: 18478730197 Pra7dt ELECTRICAL SYSTEM CONTENTS CHARGING SYSTEM DESCRIPTION (GENERATOR WITH IC REGULATOR) - CHARGING QUTPUT CHECK REMOVAL AND DISASSEMBLY INSPECTION -~ REASSEMBLY AND REMOUNTING REASSEMBLY INFORMATION - IGNITION SYSTEM DESCRIPTION INSPECTION ~ STARTER SYSTEM DESCRIPTION REMOVAL AND DISASSEMBLY INSPECTION -- REASSEMBLY « STARTER RELAY INSPECTION SIDE-STAND/GNITION INTERLOCK SYSTEM DESCRIPTION INSPECTION - COMBINATION METER REMOVAL AND DISASSEMBLY INSPECTION - ENGINE COOLANT TEMPERATURE METER INSPECTION -- FUEL LEVEL INDICATOR - INSPECTION - LAMPS --- = HEADLIGHT TAIL/BRAKE LIGHT TURN SIGNAL LIGHT SWITCHES RELAY STARTER RELAY SIDE-STAND RELAY - TURN SIGNAL RELAY - BATTERY - SPECIFICATIONS INITIAL CHARGING SERVICING RECHARGING OPERATIONMAY-25-2082 81:35P FROM: TO: 18478730197 Pravda 8-1_ ELECTRICAL SYSTEM CHARGING SYSTEM DESCRIPTION (GENERATOR WITH IC REGULATOR) The generator features a solid state regulator that is mounted inside the generator. All regulator com- ponents are enclosed into a solid mold, and this unit is attached to the brush holder frame. The regu- lator voltage setting cannot be adjusted. Two brushes carry current through the two slip rings to the rotor coil mounted on the rotor. ‘The stator windings are assembled on the inside of a laminated core that forms part of the generator ¢ housing. A rectifier bridge connected to the stator windings contains six diodes, and electrically changes the stator A.C. voltages to a D.C. voltage which appears at the generator output terminal, @ Rotor @ Motor cow © Stator coil ( © Sip ring ® Brosh © IC raptor © Brush holder 8 Barer terminal c52002 O1:35P FROM: CHARGING OUTPUT CHECK * Remove the front seat, * Start the engine and keep it running at 5 000 r/min. = Measure the DC voltage between the battery terminals @ and © with a pocket tester. If the tester reads under 13.5V, check the stator coil, rectifier and IC regulator mounted in the generator. CAUTION: If the pocket tester is set to read current or resistance and a voltage is applied across the test probes, damage will result. Therefore, it is important that the tester knob on the pocket tester be set the proper position before making any measurements. NOTE: When meking this test, be sure that the battery Is fully charged condition. 09900-25002: Pocket tester Tester knob indication; DC25V : ‘Above DC13.5V at STD charging output G Goo as REMOVAL AND DISASSEMBLY ‘* Remove the seats and frame cover assembly. * Remove the lower cowling. (Refer to page 7-2.) * Disconnect the generator lead wires coupler. * Remove the throttle stop screw bracket bolt @. ‘© Remove the generator by removing the bolts. TO: 18478730197 Prat ELECTRICAL SYSTEMMAY-25-2082 81:36P FROM: TO: 18478730197 41d 3 ELECTRICAL SYSTEM '* Remove the generator end cover. * Disconnect the stator coil lead wires @ and battery load wire ® by using a soldering iron. * Remove the brush holder, IC regulator and rectifier to re- move three screws. ‘© Remove the two nuts. ‘+ Remove the generator, housing @ from generator end housing @ . * Remove the four bearing retainer screws.TO: 18478730197 P:Sv4t ELECTRICAL SYSTEM 6-4 = Remove the rotor @ from generator end housing @ by using a hand-press @ as shown. INSPECTION ROTOR BEARING Inspect the rotor bearings for abnormal noise and smooth rotation to rotate them by hand. If there is anything unusual, remove the bearing with a bear- ing puller. (09913-60910: Bearing puller (40—60 mm) CAUTION: The removed bearing should be replaced with a new one. STATOR COIL CONTINUITY CHECK Check the continuity between the lead wires of the stator with a pocket tester. If there is no continuity, replace the stator. Also check that the stator core is insulated. 09900-25002: Pocket tester Tester knob indication: X 19 range ROTOR COIL CONTINUITY CHECK ‘Check the continuity between the two slip rings of the ro~ tor with @ pocket tester. if there is no continuity, replece the rotor. Also check that the rotor is insulated. 09900-25002: Pocket tester Tester knob indication: x 19 range5.6 ELECTRICAL SYSTEM TO: 18478730197 P6741 SLIP RING If the slip ring surface is dirty, polish it with #400 fine emery paper to protect the charging performance. After polishing, wipe the slip ring with a clean dry cloth. 09900-20102: Vemier calipers (200 mm) Service Limit 14.0 mm (0.6 in) Slip ring 0.0. CARBON BRUSH Measure the length of the brushes as shown. If it exceeds the service limit, replace them with new one: 09900-20102: Vernier calipers {200 mm} Service Limit 4.5 mm (0.18 in) Brush length RECTIFIER ‘Check the continuity between terminals and ground. Put one tester lead to terminal “8” and the other lead to ground or other terminals: then swap the two leads. Of the two tester indications, one should be continuity, and the other should be infinity (non continuity). If not, replace the rectifier as- sembly. 09900-25002: Pocket tester Tester knob indi ion; X 10 range me (Ground)MAY-25-2082 81:37P FROM: TO: 18478730197 ieeee ELECTRICAL SYSTEM. 6.6 Ic REGULATOR Use a variable DC power source, switch, bulb and pocket tester, check the IC regulator, which re- quires two steps described below: First check: Set the variable DC power source to 12V and turn the s not light, replace the IC regulator. If the bulb is lighting ON, Second check: Under the above condition, set the variable DC power source to 14.5V, if the bulb goes out, the IC regulator is in good condition. If the bulb remains lit, replace the IC regulator. 09900-25002: Pocket tester Tester knob indication: DCZ5V itch to the ON position. If the bulb'does IC regulator has passed the first check. IC regulator (nav 3.40) E: Ground6-7 ELECTRICAL SYSTEM TO: 18478730197 Peat REASSEMBLY AND REMOUNTING Reassemble and remount the generator in the reverse ord- er of disassembly and removal, Pay attention to the follow- 19 points: * Apply grease to the lip of the cil seal. 99000-28030; SUZUKI SUPER GREASE “A” CAUTION: The removed oil seal should be replaced with a new one. = Install the bearing by using a hand-press as shown. * Apply a small quantity of THREAD LOCK “1342” to the bearing retainer screws. 99000-32050: THREAD LOCK “1342 * Install the rotor and bearing by using hand-press as shown,MAY-25-2082 81:37P FROM: NOTE: ‘Before reinstalling the slip ring side bearing to generator end housing, turn the expander ring and align the expander ring lug with the center of chamfer face of bearing outer race. « Fit 2 new O-ring to,the generator end housing. = Align the lug @ of the generator end cover with the groove © of the lead wire grommet. TO: 18478730197 O11 ELECTRICAL SYSTEM _ 68 ing caver No.1 Expander ring. ating Saae Bearing cover No.2 Rotor “sig Expander ring tug chamfer faceMAY-25-2082 81:3EP FROM: TO: 18478730197 .9_ELECTAICAL SYSTEM REASSEMBLY INFORMATION @ 0m 6 Sener ning C @ Oilseai @ Rectifier @ Generator end housing @ Rectifier cover Tightening torque @ Bearing seat IC regulator Tee on ee ® Bearing Ganerator load wire @ Besring retainer @ Brush holder & 037-055 | 26-40 C Rotor © Brush cover (022-033 | 15-25 erring cover o.2 Generar ee cover © oa7-055 | 26-40 | @ Bearing @ Bearing cover No. 1 2 2.1-29 | 15.0-21.0 |MAY-25-2082 81:3EP FROM: TO: 18478730197 Praia ELECTRICAL SYSTEM 6-10 IGNITION SYSTEM (DIGITAL IGNITOR) DESCRIPTION ‘The fully transistorized ignition system consists of a signal generator, ignitor unit (including 8-BIT MICROCOMPUTER and CERAMIC 4MHZ VIBRATOR), ignition coils and spark plugs. The charac- ition timing is programmed and stored in the "ROM" (READ ONLY MEMORY] of the ignitor unit. ‘The signal generator comprises the rotor tip and pickup coil. ‘The signal generator is mounted at the right end of the crankshaft. The i duced signal in the signal generator Is sent to wave-form arrangement circuit, and CPU receives this signal and calculates the best ignition timing from the signal of ceramic vibrator and data stored in the ROM. The CPU out- puts signal to the transistor of the |.G. coll output circuit which is connected to the primary wind- ings of the ignition coil which is turned OFF and ON accordingly, thus it induces the secondary current ‘on the ignition coil secondary windings and produce the spark between spark plug gaps. Ignition cut-off citcuit is incorporated in the ignitor unit to prevent over-running engine. If engine rimin. reaches 12 800 r/min., this circult cuts off the ignition primary current for all spark plugs. CAUTION: Engine can run over 12 800 r/min. without load, even if the ignition cut-off circuit is effective, and it may cause engine damage. Do not run the engine without load over 12 800 r/min. at anytime. Engino Side stop switch stand relay lgnitor G col outoS Greuit Ro: Red (0/8 : Orange with Biack tracer ‘GAW : Orenge with White tracer Black with Red BY! Black with Yellow wocee BAY: Bln with Whi ‘OLY : Orange with Yellow tracerMAY-25-2082 81:46P FROM: TO: 18478730197 12 1_ ELECTRICAL SYSTEM. INSPECTION IGNITION COIL (Checking with Electro Tester) * Remove the seats, frame cover assembly and fuel tank. (Refer to pages 7-5 and 4-5.) ‘+ Remove the ignition coils. NOTE: Moke sure that the three-needle sparking distance of elec- t1o tester is set at & mm (0.2 in). ‘+ With the tester and jumper wire, test the ignition coil for sparking performance in accordance with the following ‘two steps. STEP @ : Connect the jumper wire to the spark plug cap and ignition coil ground. STEP @ : Switch over the jumper wire to the other plug cap and ground. If no sparking or orange color sparking occures in the above conditions, it may be caused by defective coil. 09900-28106: Electro tester ‘Spark performance Over 8 mm (0.3 in) IGNITION COIL (Checking with Pocket Tester) ‘* A SUZUKI pocket tester or an chm meter may be used, tinuity will be noted with these approximate ohmic values. 09900-25002: Pocket tester @ tap—O tap Primary 2.4~3.20 Tester range: (X 10) Plug cap—Plug cap Secondary 30-40 ka Tester range: (X 1k) SIGNAL GENERATOR (Checking with Pocket Tester) * Remove the front seat and disconnect the lead wires. * Measure the resistance between lead wires. If the resistance is infinity or less than the specifications, the signal generator must be replaced. 09900-25002: Pocket tester ‘Approx. 135-2008 Signal coil resistance {Block Green} Tester knob indication: X 1000 rangeMAY-25-2082 81:46P FROM: TO: 18478730197 Prevde, ELECTRICAL SYSTEM 2 ‘SPARK PLUGS ‘* Remove the seats, frame cover assembly and fuel tank. (Refer to pages 7-6 and 4-6.) ‘© Remove all the spark plugs. Carbon Deposit ‘Check to see the carbon deposit on the plug. If the carbon is deposited, remove it with a spark plug cleaner machine or carefully using a tool with a pointed end. Spark Plug Gap Measure the plug gap with a thickness gauge if it If not, adjust it to the following gap. 09900-20803: Thickness gauge Standard Spark plug gap 0.70.8 mm (0.028—-0.032 in) Electrode’s Condition Check to see a worn or burnt condition of the electrode. If it is extremely worn or burnt, replace the plug. Also replace the plug if it has @ broken insulator, damaged thread, etc. Heat Range NGK CR9E should be used as the standard. However. the heat range of the spark plug should be selected to meet the requirements of speed, actual load, fuel and etc. Proper heat range would be indicated if all insulators were LIGHT Reece BROWN in color. If they are baked white, they should be Orono eo es2 in) teplaced with @ cold type plug NGK CR10E or NIPPON- DENSO U3TESR-N. [ Standard | Cold type | Hot type BE, NGK CRSE CRIOE ‘CREE Ni IPPONDENSO | U27ESR-N | U31ESR-N | U24ESR-N CAUTION: Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be deposited on the screw portion of the plug hole and engine damage may result.MAY-25-2082 81:46P FROM: TO: 18478730197 P42 13 ELECTRICAL SYSTEM IGNITOR UNIT (Checking with Digital Ignitor Checker) This section explains the checking procedure for the ignitor unit using Digital Ignitor Checker (spe- cial tool). With this checker, the ignitor unit can be checked either on the machine or off the machine. The following explains the checking procedure on the machine. 09931-94430: Digital ignitor checker WIRING PROCEDURE: '* Remove the front seat. ‘* Disconnect two ignitor lead wire couplers @ at the igni- tor unit. * Prepare the ignitor checker lead wire “MODE 1” @) which comes suppl the ignitor checker and connect its end to the ignitor unit and another end to the checker. * Connect the power source leads @ to the battery. CAUTION: * Be sure that the BLACK iead is connected to the battery © terminal and RED lead to the @ terminal. * Before connecting the power source leads, make sure that both “POWER” button and “START” switch are in “off” position (POWER button not depressed). NOTE: Be sure that the battery used Is in fully-charged condition. CHECK PROCEDURE: With all the lead wires properly connected, check the igni- Ganeaneo tor unit in the following four steps. — en First Step: S| adaoda| & Depress “MODE 1” button then “POWER” button. This ar = rer time, “POWER lamp should come on, if not, battery is un- we Q dercharged. i eee CMAY-25-2082 81:47P FROM: TO: 18478730197 Pate ELECTRICAL SYSTEM 6-14 Second Step: Set “REVOLUTION” dial pointer to "'.2”” position in which the checker produces the ignition primary current pulses MONITOR simulating 200 r/min of engine revolution when “START” switch is turned on. With “START” switch is turned to ON oe position, check that three “MONITOR” lamps turn on and Tach? off in slow frequency in order of @-@—@ or D-@-@ DENI as illustrated. Third Step: Turn “REVOLUTION” dial up gradually (assuming the en- REVOLUTION gine gradually revved up) and check that the MONITOR lamp flash frequency as explained in the second step above in- creases. As the dial pointer passes beyond the graduation “4°” (@ 000 rimin), all the three lamps should show con- tinuously lighted. When REVOLUTION dial pointer reaches between "12" and “13” (12 000—13 000 r/min}, MONITOR “IG1” and “IG2” x1000rpm lamps should go off while “TACHO” lamp stays on. This Is because the ignition “cut-off” provided in the RF600R ignition system functions at 12 800 100 r/min, IF the lamps go off at the graduation below ’’12”, the engine can not : : Perform properly and therefore the ignitor unit must be replaced Raavaaed = Fourth Step: Turn "START" switch to STOP position. If the “IG1" or “1G2"", or both lamps remain light more than 5 seconds, the ignitor unit must be replaced. IGniToR POSAXAANRARARLY ATTAIN TTMAY-25-2082 81:47P FROM: TO: 18478730197 412 6-15_ ELECTRICAL SYSTEM. STARTER SYSTEM DESCRIPTION Cc The starter system is shown in the diagrem below: namely, the starter motor, starter relay, side-stand relay, side-stand switch, neutral switch, clutch lever position switch, starter switch, engine stop switch, 1G switch and battery. Depressing the starter switch (on the right handlebar switch box) energizes the relay. causing the contact points to close which connects the starter motor to the battery. The motor draws about 80 amperes to start the engine. (For £03, 28 and 33 models) Enging stop Ignition Clutch lever position switch switch switch ‘Side-stand awiteh REMOVAL AND DISASSEMBLY * Remove the lower cowling assembly. (Refer to page 7-2.) * Disconnect the starter motor lead wire and remove the starter motor by removing the mounting bolts. NOTE: Ititis difficult to remove the starter motor, remove the water hose mounting bolts t0 provide additional space.MAY-25-2082 81:47P FROM: TO: 18478730197 ELECTRICAL SYSTEM 6-18 12 ‘= Disassemble the starter motor as shown in the illustration. Th1942: Apply THREAD LOCK "1342", G | Apply GREASE “ Moly : Apply MOLY PASTE. @ Oxring (2 pos) @ O+ing @ Housing end (tnside) @ O-ting (2 pes) @ Starter mator case @© Washer set © Armature @ Shim set ® Brush holder @ Brush epring (4 pes) @ Brush @® Housing end (Outside) INSPECTION CARBON BRUSH When the brushes are worn, the motor will be unable to produce sufficient torque, and the engine will be difficult to tum over. To prevent this, periodically, measure the length of the brushes with a vernier calipers, replacing them when they are too short or chipping. 09900-20102: Verni calipers (200 mm) : Service Limit Brush length 6 mm (0.2 in} COMMUTATOR if the commutator surface is diny, starting performance decreases. Polish the commutator with #400 or similar fine ‘emery paper when itis dirty. After polishing it, wipe the com- ‘SEGMENT mutator with a clean dry cloth. Measure the commutator under cut @ with a vernier calipers. ica 09900-20102: Vernier calipers (200 mm) Service Limi Commutator under-cut _ 0.2 mm (0.008 in)MAY-25-2082 81:48P FROM: TO: 18478730197 P7742 5A17_ELECTRICAL SYSTEM ARMATURE COIL Using a pocket tester, check the coil for open and ground by placing probe pins on each commutator segment and ro- tor core (to test for ground) and on any two segments at various places (to test for open), with the brushes lifted off the commutator surface. If the coil is found to be open-circuited or grounded replace the armature. Continuous use of a defective armature will cause the starter motor to suddenly fail. 09900-25002: Pocket tester Tester knob indication: X 19 range OIL SEAL ‘Check the seal lip for damage or oil leakage. If any damage is found, replace it. REASSEMBLY O-RING CAUTION: Replace the O-rings with new ones to prevent oll leakage and moisture. HOUSING END (inside) ‘© Apply grease to the lip of oil seal. (Refer to page 6-16.) 99000-25030: SUZUKI SUPER GREASE “A” HOUSING END (Outside) : ‘* Apply a small quantity of SUZUKI MOLY PASTE to the armature end. (Refer to page 6-16.) 99000-25140: SUZUKI MOLY PASTE * Apply a small quantity of THREAD LOCK “1342” to the starter motor housing screws. (Refer to page 6-16.) 99000-32050: THREAD LOCK "1342"MAY-25-2082 81:48P FROM: TO: 18478730197 Pode ELECTRICAL SYSTEM_6-18 STARTER RELAY INSPECTION = Remove the seats and frame cover assembly. * Disconnect the starter motor lead wire and battery lead wire at the starter relay which is located behind the left frame cover. connect the Ik 1d wire coupler from the starter relay. ‘+ Apply 12 volts to @ and @ terminals, inspect the con- tinuity between the terminals, positive and negative. If the starter relay is in sound condition, continuity is found. 09900-25002: Pocket tester Tester knob indication: X 12 range CAUTION: * Do not apply a battery voltage more than 5 seconds to the starter relay as it may overheat and cause damage to the relay coil. * Check the coil for “‘open”, “ground” and ohmic resistance. ‘The coil is in good condition if the resistance is as follows. 09900-25002: Pocket tester Tester knob indication: X 19 range Standard Starter relay resistan 3-52 STARTER RELAY CIRCUIT DIAGRAM ‘To starter motorMAY-25-2082 81:48P FROM: TO: 18478730197 viz 6:19 ELECTRICAL SYSTEM SIDE-STAND/IGNITION INTERLOCK SYSTEM DESCRIPTION This side-stand/ignition interlock system is to prevent starting the motorcycle with the left down. The system is operated by an electric circuit provided between the battery and ignition coil, Side-stand Engine stop Fuse Tonition switch oy, switeh aes omoto Starter motor Bich Clutch lever position switch (For £03, 28 ‘and 33 models) IG ware COLOR, O/B : Orange with Black OW: Orange with White {YIG = Volow with Green tracer ‘The circuit consists of relay, lamp, diode and switches and decides to live the ignition coil depending on the position of the TRANSMISSION and SIDE-STAND with the neutral and side-stand switches working mutually. The ignition coil lives only in two situations as follows. 1. Transmission; “NEUTRAL (ON) Side-stand: “DOWN (OFF)'’ The current flow @tums ON” the relay and the ignition coil lives even the side-stand is kept down. This is or warming up the engine. SIDE-STAND. RELAY ON" IGNTION con. DIODE NEUTRAL SW. “ON SIDE-STAND SW. SIDE-STAND, "DOWN POSITION”MAY-25-2082 81:49P FROM: TO: 18478730197 ELECTRICAL SYSTEM 6.20 10712 2. Side-stand: ““UP-RIGHT (ON1"” The current flow @turns ““ON" the relay and th started at any transmission position. inition coil lives, The engine can be easily SIDE-STANO IGNITION Sw. RELAY “ON” an IGniTion BATTERY = INSPECTION If the interlock system does not operate properly, check each component. If any abnormality is found, replace the com- ponent with a new one. 09900-25002: Pocket tester Diode The diode is located behind the left frame cover. The diode can pass current only in one direction. * Check the continuity between ® and @). If one way con- tinuity the diode is in good condition. * Also check the continuity between @ and @ as required.52002 B1:49P FROM: ELECTRICAL SYSTEM Neutral switch ‘The neutral lead wire coupler is located behind the left frame cover. * Remove the seats and frame cover assembly. * Disconnect the neutral switch lead and check the con- tinuity between Blue and Ground with the transi in “NEUTRAL”. Side-stand switch Green Black/White ne o_o (UP-right position) OFF. {Down position) Side-stand/ignition interlock relay, The side-stand/ignition interlock relay is located behind the right frame cover. * Remove the seats and frame cover assembly. First, check the insulation between @ and @ terminals with pocket tester. Then apply 12 volts to @ and @ terminals, @ to @ and © to @ , and check the continuity between Dand®. If there is no continuity, replace it with a new ane. 09900-25002: Pocket tester Tester knob indication: X 10 range TO: 18478730197 Priit2COMBINATION METER REMOVAL AND DISASSEMBLY ‘* Remove the combination meter. * Disassemble the combination meter as follows. TO: 18478730197 Piiet2 ELECTRICAL SYSTEM 6.22 INSPECTION Using the pocket tester, check the conti wires in the diagram on next page. If the continuity measured is incorrect, replace the respec: tive parts. ity between lead 09900-25002: Pocket tester Tester knob indication: X 19 range NOTE: When making this test, it is not necessary to remove the combination meter.MAY-25-2002 @1:52P FROM: 6.23 ELECTRICAL SYSTEM TO: 18478730197 P1710 La: TURN (R) @ ©: NEUTRAL, OIL, FUEL Y: HIGH BEAM B: TURN (Ly BIR: TACHO SIGNAL @ Gr: LLUM® YiB: FUEL © 0: TACHO, TEMP ® @ BMW: HIGH BEAM © B/W: ILLUMI, TACHO © Teme © pve: NeuTRAL © — |i Trobe ot |G Fiabe ot] GI: Green with Yellow tracer Ue Tester to! | Tester to: Orange or o Gy Black TURN 8 ig # Black with led tracer TACHO SIGNAL] — Br ew Yellow HIGH BEAM Y Bw : lah een TURN a s Bue witn Black wacer NEUTRAL 9 28 Black with White tracar TECURAT Se Gil Black with Blue tracer TEMP g Bier : Black with Brown tracer TEM 9 BIG ! Black with Groen tracer TACHO o ew, Black with White tracer FUEL 2 Ye Yellow with Black tracerMAY-25-2002 @1:51P FROM: TO: 18478730197 P2710 ELECTRICAL SYSTEM 6.24 ENGINE COOLANT TEMPERATURE METER INSPECTION As the coil spring Is installed on the needle shaft of the en- gine coolant temperature meter, the needle is forcibly back ‘to the original position when ignition switch Is turned OFF. To test the engine coolant temperature meter two different checks may be used. The first, and simplest test will tell if the meter is operating but will not indicate the meters ac- curacy throughout the range. To perform this test, remove the service lid on the lower cowling and disconnect the B/G lead wire of the engine coolant temperature meter from the engine coolant temper- ature gauge. Connect a jumper wire between B/G wire com- ing from the main wiring harness and engine ground. With the ignition switch turned on, the engine coolant tempera- ture meter should indicate “H”. B/G: Black with Green tracer The second test will check the accuracy of the meter in the “HH” and C”" positions. 2 Connect 2 153.9-ohm resistor between the B/G lead wire of the engine coolant temperature meter and engine ground, The engine coolant temperature meter is normal if its pointer idicates the @) position when the specified voltage is ap- plied to the circuit and if its pointer indicates the @) po: yn when the resistor is changed to 16.1 ohms. If either one of both indications are abnormal, replace the engine coolant temperature meter with a new one. The relation between the position of the engine coolant tem- perature meter and resistance is shown in the following table. POSITION. RESISTANCE ® 153.90 ® 16.19 For inspecting the engine coolant temperature gauge, refer to page 5-9.MAY-25-2002 @1:51P FROM: TO: 18478730197 P3310 6:26 ELECTRICAL SYSTEM FUEL LEVEL INDICATOR 1G. switch Fuel level indicetor switch INSPECTION + Remove the seats and frame cover assembly, (Refer to page 7-6.) * With the engine has started, disconnect the two lead wires going into the fuel level indicator switch, connect the lead wires from the main wiring harness with a jumper lead and check whether the fuel level indicator light a “LIGHT” is indicated, the circuit of fuel level indicator light is in good condition. If the fuel level indicator light does not light, replace the indicator bulb or repair the ci cuit connection. If the bulb is in good condition, the level indicator switch may be faulty, replace the indicator ‘switch with a new one or inspect the fuel level indicator switch. ‘= Remove the fuel tank. (Refer to page 4-6.) ‘+ Remove the fuel level indicator switch from the fuel tank.MAY-25-2082 81:51P FROM: * Connect 12V battery to the fuel level indicator switch and (ground through a 3.4W bulb. The bulb should light up after several seconds if the switch is in good condition. ‘= When the switch is immersed in water under the above condition, the bulb should go out. If the bulb remains lit, replace the fuel level indicator switch. TO: 18478730197 4710 ELECTRICAL SYSTEM 6.26 Test bulb 12 3.4W ravi] Battery l Test bulb 42 3.4WMAY-25-2082 81:5eP FROM: TO: 18478730197 P:5710, 6:27 ELECTRICAL SYSTEM LAMPS, HEADLIGHT NOTE: Adjust the headlight, both vertical and horizontal, after reassembling. TAIL/BRAKE LIGHTMAY-25-2082 81:5eP FROM: TO: 18478730197 P6710, ELECTRICAL SYSTEM 6.28 TURN SIGNAL LIGHT CAUTION: Do not overtighten the lens fitting screws. SWITCHES Inspect each switch for continuity with the pocket tester referring to the WIRING DIAGRAM. If any abnormality is found, replace the respective switch assemblies with new ones. (Refer to the chapter 8 for wiring diagram.) 09900-25002: Pocket tester Tester knob indication: X 19 range OIL PRESSURE SWITCH © Continuity, when engine is stopped. © No continuity, when en; i Black or Green/Yellow oon ON o——+— OFF NOTE: Before inspecting the oil pressure switch, check if the en- = gine oil level is enough,MAY-25-2082 81:5eP FROM: TO: 18478730197 P:7710 629 ELECTRICAL SYSTEM RELAY STARTER RELAY The starter relay is located behind the left frame cover. (Refer to page 6-18 for details.) SIDE-STAND RELAY ‘The side-stand relay is located behind the right frame cover. (Refer to page 6-21 for details.) TURN SIGNAL RELAY ‘The tum signal relay is located behind the right frame cover. tf the turn signal ight does not light. Inspect the bulb or repair the circuit connection. If the bulb and circuit connection checked are correct, the turn signal relay may be faulty, replace it with a new one, NOTE: Be sure that the battery used is in fully-charged condition.MAY-25-2082 81:5eP FROM: See eee TO: 18478730197 P8710 ELECTRICAL SYSTEM. 6.30 BATTERY SPECIFICATIONS Type designation YTX9-85 Capacity 12V, 28.8 kG (8 ANVTOHR feces 1.320 at 20°C (68°F) INITIAL CHARGING Filling electrolyte ‘* Remove the aluminum tape © sealing the battery elec- trolyte filler holes. ‘+ Remove the caps @ . NOTE: * After filling the electrolyte completely, use the removed cap @ as the sealed caps of battery-filler holes. * Do not remove or pierce the sealed areas @ of the elec- trolyte container. * Insert the nozzles of the electrolyte container into the bat- tery’s electrolyte filler holes, holding the container firmly 30 that it does not fall. Take precaution not to allow any of the fluid to spill. ‘+ Make sure air bubbles are coming up each electrolyte con- tainer, and leave in this position for about more than 20 minutes.MAY-25-2082 81:53P FROM: 1 ELECTRICAL SYSTEM TO: 18478730197 P:9710 NOTE: if no alr bubbles are coming up from a filler port, tap the bottom of the two or three times. Never remove the container from the battery. * After confirming that the electrolyte has entered the bat tery completely, remove the electrolyte containers from ‘the battery. Wait for around 20 minutes. © Insert the caps into the filler holes, pressing in firmly so that the top of the caps do not protrude above the upper surface of the battery’s top cover. CAUTION: * Never use anything except the specified battery. * Once install the caps to the battery: do not remove the caps. * Using SUZUKI pocket tester, measure the battery voltage. ‘The tester should indicate more than 12,5—12.6V (DC) as shown in the Fig. If the battery voltage is lower than the specification, charge the battery with a battery charg- er. (Refer to the recharging operation.) NOTE: Initial charging for a new bettery 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, then this can be cleaned away with sandpaper. Insert the caps firmly. 0 seconds! (at 25°C) To (Minutes)MAY-25-2082 81:53P FROM: TO: 18478730197 P:10718 ELECTRICAL SYSTEM 6.32 RECHARGING OPERATION * Using the pocket tester, check the battery voltage. If the voltage reading is less than the 12.0V (DC), recharge the battery with @ battery charger. CAUTION: When recharging the battery, remove the battery from the motorcycle. NOTE: Do not remove the caps on the battery top while recharging. Recharging time: 4 for one hour or 0.9A for 5 haurs CAUTION: Be careful not to permit the charging current to exceed 4A. at any time. * After recharging, wait for more than 30 minutes and check the battery voltage with a pocket tester. * If the battery voltage is less than the 12.5V, recharge the bettery again. «© if battery voltage is still less than 12.5V, after recharg- ing, replace the battery with a new one. + When the motorcycle is not used for a long period, check the battery every 1 month to prevent the battery dis- charge. Cha ev) 18 ” 161 13 1 ing period Stop charging O10 2030408000 Time inhinutos) w (ar 0°—40°C) 14 a 2 n 10 7607850 ‘orm Battery charged conditionMAY-25-2002 81:54P FROM: TO: 18478730197 Pri747 CHASSIS | CONTENTS: COWLING AND FRAME COVER 1 REMOVAL - 2 REMOUNTING 6 FRONT WHEEL Z REMOVAL - 2 INSPECTION AND DISASSEMBLY. 7-8 REASSEMBLY AND REMOUNTING -- 7-9 TIRE AND WHEEL 7-12 TIRE REMOVAL 712 INSPECTION -- 7-14 TIRE MOUNTING - 718 FRONT BRAKE «- 27 BRAKE PAD REPLACEMENT ZA CALIPER REMOVAL AND DISASSEMBLY 7-19 CALIPER INSPECTION 7-20 CALIPER REASSEMBLY 20 DISC SERVICING - 7 DISC INSPECTION 7 MASTER CYLINDER MASTER CYLINDER INSPECTION MASTER CYLINDER REASSEMBL FRONT FORK REMOVAL A INSPECTION «: REASSEMBLY AND REMOUNTING « SUSPENSION SETTING STEERING 7-30 REMOVAL AND DISASSEMBLY --- 7-30 INSPECTION 7-31 DISASSEMBLY - 7-31 REASSEMBLY AND REMOUNTING - STEERING TENSION ADJUSTMENT IGNITION SWITCH ~~ REAR BRAKE BRAKE PAD REPLACEMENT CALIPER REMOVAL AND DISASSEMBLY - CALIPER INSPECTION ... CALIPER REASSEMBLY AND REMQUNTING MASTER CYLINDER REMOVAL AND DISASSEMBLY MASTER CYLINDER INSPECTION MASTER CYLINDER REASSEMBLY AND REMOUNTING REAR WHEEL REMOVAL AND DISASSEMBLY INSPECTION AND DISASSEMBLY REASSEMBLY AND REMOUNTING REAR SUSPENSION REMOVAL -- INSPECTION REASSEMBLY AND REMOUNTING REASSEMBLY ONTO FRAME --. FINAL INSPECTION AND ADJUSTMENT SUSPENSION SETTING -#55P FROM: MAY-25-2002 @1 7.4_ CHASSIS COWLING AND FRAME COVERMAY-25-2082 81:55P FROM: TO: 18478730197 REMOVAL COWLING ASSEMBLY AND COWLING BRACE 1, Remove the cowling upper panels of front by removing the screws, left and right. 2. Remove the cowling upper panels of rear by removing the screws, left and right. 3. Remove the service lids on the lower cowling by remov- ing the screws, left and right. 4, Remove the lower cowling of rear by removing the screws and nut @.TO: 18478730197 P4747 5. Remove the lower cowling assembly by removing the screws and bolts, left and right. 6. Remove the rear-view mirrors by removing the bolts, left and right. 7. Remove the front turn signal lights after disconnecting the their lead wire couplers, left and right. 8. Disconnect the headlight and position light lead wire couplers. 9, Remove the upper cowling along with the screen and headlight.MAY-25-2082 81:56P FROM: TO: 18478730197 P:S47 CHASSIS 7-4 40, Remove the center panel. 11. Disconnect the various lead wire couplers. 12, Disconnect the speedometer cable. 13. Remove the cowling brace along with the combination meter by removing the bolts and nut.52802 O1:56P FROM: TO: 18478730197 6/17 5 CHASSIS FRAME COVER ASSEMBLY 1. Remove the front seat with the ignition key. 2. Remove the rear seat with the seat lock lever. 3. Remove the pillion rider grabber mounting bolts after removing the caps @) . 4, Remove the frame cover mounting screws @ - 5. Extract the hooked parts of frame cover, left and right. #1 hooked part 6. Remove the frame cover after disconnecting the tail/brake light lead wire coupler.May-25-2002 17! f 2082 @1:56P FROM: To: 18478730197 TAT ei REMOUNTING Remount the cowling and frame cover in the reverse order of its removal. (Refer to pages 8-23, 8-24 and 8-25.)TO: 18478730197 P8747 7:7 CHASSIS FRONT WHEEL ® oT G_: Apply SUPER GREASE ""A’ ‘Th1360: Apply THREAD LOCK SUPER "94360", Tightening torque ITEM [_Nem kgm Wott @ [50-20 [75.0-8.0 |36.0—58.0] @ | 18-28 | 1.8-2.8 [13.0—20.0] REMOVAL 1, Remove the lower cowling. (Refer to page 7-2.) 2. Support the motorcycle with a jack or # wooden block. 3, Loosen the axle pinch bolts. 4. Loosen the axle shaft. 5. Remove the brake calipers, left and right. 6. Remove the axle shaft and front wheel. CAUTION: * Do not operate the brake lever while dismounting the brake calipers. * Hang the brake calipers on the motorcycle frame with a string etc,, taking care not to bend the brake hose.TO: 18478730197 P9747 CHASSIS _7-8 7. Remove the both breke discs off the front wheel by removing the mounting bolts. INSPECTION AND DISASSEMBLY ‘SPEEDOMETER GEARBOX DUST SEAL Inspect the lip of dust seal for damage. TIRE Refer to page 7-12. 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 for abnormal noise and smooth rotation. Replace the bear- ing if there is anything unusual. AXLE SHAFT Using @ diel gauge, check the axle shaft for runout and replace it if the runout exceeds the limit. 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 checked as shown doos not excead the service limit. An excessive runout is usually due to worn or loosen wheel bearings and can be reduced 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)MAY-25-2082 81:57P FROM: TO: 18478730197 P:1017 9 CHASSIS ‘+ Drive out both wheel bearings by using the special tool in the following procedures. (09941-60111: Bearing remover tool into the wheel bearing. ‘+ After inserting the wedge bar from the opposite side, lock the wedge bar in the slit of the special tool. * Drive out the wheel bearing by knocking the wedge bar. CAUTION: The removed bearings should be replaced with new ones. REASSEMBLY AND REMOUNTING Reassemble and remount the front wheel in the reverse order of removal and disassembly. Pay attention to the following points: WHEEL BEARING = Apply grease to the bearing before installing. 99000-25030; SUZUKI SUPER GREASE ‘© Install the wheel bearings as follows by using the special tool, 09924-84510; Bearing installer set Nore: First install the left whee! bearing, then install the right wheel bearing. The sealed cover on the bearing is positioned out- side, Refer to page 7-11 for details. BRAKE DISC ‘© Make sure that the brake disc is clean and free of any greasy matter. Apply THREAD LOCK SUPER "1360" to the disc mounting bolts and tighten them to the spe fied torque. Tightening torque: 18-28 Nem (1.8=2.8 kg-m, 13,0—20.0 lb-ft) 99000-32130: THREAD LOCK SUPER “1360""MAY-25-% TO: 18478730197 SPEEDOMETER GEARBOX '* Before installing the speedometer gearbox, apply grease 10 its dust seal lip and align the drive lugs © to the recess- ‘es of the wheel hub and attach the speedometer gear box to the wheel hub. 99000-25030: SUZUKI SUPER GREASE “A” ‘* Set the stopper on the speedometer gearbox to the lug @ on the left front fork. BRAKE CALIPER * Tighten the brake caliper mounting bolts to the specified torque. Tightening torque: 20—30 Nm * {2.03.0 kg-m, 14.5—21.5 lb-ft) NOTE: Push the pistons all the way into the caliper and remount the calipers. AXLE SHAFT # Tighten the axle shaft to the specified torque. Tightening torque: 50-80 N-m {8.0~8.0 kg-m, 36.0—58.0 Ib-ft) ‘# Tighten the pinch bolt to the specified torque. Tightening torque: 18-28 Nem (1.8—2.8 kg-m, 13.0—20.0 Ib-ft)MAY-25-2082 81:5EP FROM: TO: 18478730197 12747 11, CHASSIS G_: Apply SUPER GREASE “A” n1860: Apply THREAD LOCK SUPER mW "1360" =f C 20-30 Nm 20-30 Nm (F2538'82,) Gerson jasm21s let) 14,521.81 19-28 Nm 1,8—2.8 kgm (Boze) ) € 50-82 Km) 36.0=50.0 te e 18—28 Nm (852842,) 13.0-2001h) Let Sp Right Left Right Use oa par) % Use old part Use old part cq - | seding ‘Spacer u installer on Lett bearing Left bearing ight bearing tira wie se coer tneTO: 18478730197 P1317 CHASSIS 7.12 i UU EEOe! TIRE AND WHEEL TIRE REMOVAL The most critical factor of a tubeless tire is the seal between the wheel rim and the tire bead. Be- cause of this, we recommend using 4 tire changer which is also more efficient than tire levers. For tire removal, the following tools are required. @ Tie changer stand ® Operation arm @ Tire lever © Cemer shaft © Beod pushing roter @ fim guide roller Bead breaker Rim protector © Core remover @ Air pressure gauge © Tie ubricant '* Remove the valve core from the valve stem, and deflate the tire completely. NOTE: Mark the tire with chalk to note the position @ of the tire on the rim and rotational direction @ of the tire.TO: 18478730197 P1417 3_ CHASSIS. * Place the center shaft © to the wheel, and fix the wheel with the tim holder @ « ‘= Attach the operation arm @ to the center shoft. + Attach the bead breaker @ to the operation arm, and dis- mount the bead from the rim, Turn the wheel over and dismount the other bead from the rim. «+ Install the rim guide rolier © - ‘+ Install the rim protector © , and raise the beed with the tire lever @ * Set the tire lever against the operation arm, and rotate the lever around the rim, Repeat this procedure to remove the other bead from the rim.MAY-25-2082 81:59P FROM: TO: 18478730197 15717 CHASSIS INSPECTION WHEEL Wipe off any rubber substance or rust from the wheel, and inspect the wheel rim. If any one of the following items is ‘observed, replace it with a new wheel. * A distortion or crack. eS * Any scratches or flaws in the bead seating area. 7 ) | + Wheel runout (Axial & Radial) of more than 2.0 mm (0.08 in). TIRE Thoroughly inspect the removes tire, and if any one of the following items is observed, do not repair the tire. Replace with a new one. + A puncture or a split whose total length or diameter exceeds 6.0 mm (0.24 in). * A scratch or split at the side wall. * Tread depth less than 1.6mm (0.06 in) in the front tire and less then 2.0 mm (0.08 in) in the raar tre. 09900-20805: Tire depth gauge * Ply separation, + Treed separati * Tread wear is extraordinarily deformed or distributed around the tire. * Scratches at the bead. : 7 * Cord is cut. Damage from skidding (flat spots. Abnormality in the inner liner. NOTE: When repairing a flat tire, follow the repair instructions and use only recommended repairing materials. VALVE INSPECTION Inspect the valve after the tire is removed from the rim, and replace with a new valve if the seal rubber has any splits or scratche! . é Inspect the removed valve core and replace with the new one if the seal is abnormally deformed or worn.MAY-25-2082 81:59P FROM: 745 CHASSIS. TO: 18478730197 P1617 VALVE INSTALLATION ‘Any dust or rust around the valve hole must be cleaned off. Then install the vaive in the rim. NOTE: To properly install the valve into the valve hole, apply @ spe- cial tire luburicant or neutral soapy liquid to the valve. CAUTION: Be careful not to damage the threads and lip of valve. TIRE MOUNTING e ‘* Apply a special tire lubricant or neutral soapy liquid to the tire bead. CAUTION: Never apply grease, oil or gasoline to the tire bead. ‘© When installing the tire, make certain that the directional arrow faces the direction of wheel rotation and align the balancing mark of the tire with the valve as shown. * Set the bead pushing roller @. * Rotate the operation arm around the rim to mount the bead completely. Do the bottom bead first, then the upper bead. * Remove the wheel from the tire changer, and install the valve core in the valve stem. NOTE: Before installing the valve core, inspect the core. Whee! Valve tip iveTO: 18478730197 P1717 CHASSIS. 7.18 '* Bounce the tire several times wi the tire bead expand outwards, and thus makes inflation easier. Nott Before inflating, confirm that the balence mark lines up with the valva stem. = Pump up the tire with air. WARNING: Do not inflate the tire to more than 400 kPa (4.0 kg/cm’, 56 psi). The tire could burst with sufficient force to cause severe injury. Never stand directly over the tire while inflat- ing it. NOTE: Check the “‘rim line” cast on the tire side walls. It must be equidistant from the wheel rim all the way around. If the distance between the rim line and wheel rim varies, this in- dicates that the bead is not properly seated, If this is so, deflate the tire completely, and unseat the bead for both sides. Coat the bead with lubricant, and try again. + After tire is properly seated to the wheel rim, adjust the air-pressure to the recomended pressure. Correct the wheel balance if necessary. WARNING: * Do not run a repaired tire more than 50 km/h (30 mph) within 24 hours after tire repairing, since the patch may not be completely cured. * Do not excead 130 km/h {80 mph} with a repaired tire, ‘TIRE PRESSURE [COLD INFLATION] SOLO RIDING | DUAL RIDING TIRE PRESSURE | {Pa kg/cm] psi | kPa FRONT 260 | 2.50] 36 | 260/250] 36 REAR 250 | 2.50| 36 | 290 | 2.90] 41MAY-25-2002 @2:B1P FROM: TO: 18478730197 Pit 747 CHASSIS FRONT BRAKE Tightening torque Trem | Nem B-12 15-20 6-9 20-30 15-20 @|®|O|@19) BRAKE PAD REPLACEMENT 1. Remove the caliper by removing the mounting bolts and speedometer cable guide bolt (for left caliper).52002 B2:01P FROM: TO: 18478730197 2. Remove the brake pad mounting bolt cap @ « 3, Remove the brake pads by removing the pad mounting bolt @ - CAUTION: » Do not operate the brake lever while dismounting the pads. * Replace the brake pads as a set, otherwise braking per- formance will be adversely affected. 4, Remount the new pads. WARNING: Make sure that the pads are property engaged with the guide plate as shown in the illustration. 5. Tighten the pads mounting bolt @ to the specified torque, Tightening torque: 15—20 N-m (1.5-2.0 kg-m, 11,.0—14.5 lb-ft} 6. Tighten the caliper mounting bolts @ to the specified torque. Tightening torque: 20—-30 N-m (2.0—3.0 kg-m, 14.5—21.5 Ib-ft)CALIPER REMOVAL AND DISASSEMBLY 1. Disconnect the brake hose from the caliper by remot ‘the union bolt and catch the broke fluid in a suitable receptacle. 2. Remove the brake caliper by removing the cali ing bolts and speedometer cable guide bolt (for left caliper). CAUTION: Never reuse the brake fluid left over from pre ing and stored for long periods. WARNING: 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. ious servic 3. Remove the pads. (Refer to page 7-18.) 4, Remove the caliper holder @ . §. Remove the spring @ . 6. Place a rag over the piston to prevent its popping out and push out the piston with an air gun. CAUTION: Do not use high prossure air to prevent piston damage. 7. Remove the dust seals and piston seals. TO: 18478730197TO: 18478730197 Pq cHaSsis_7.20 CALIPER INSPECTION CALIPER Inspect the caliper cylinder wall for nicks, scratches or other damage. PISTON Inspect the piston surface for any scratches or other damage. RUBBER PARTS: ‘The removed rubber parts should be replaced with new ones. CALIPER REASSEMBLY AND REMOUNTING Reassemble the caliper in the reverse order of removal and disassembly. Pay attention to the following points: CAUTION: * Wash the caliper components with fresh brake fluid be- fore reassembly. Never use cleaning solvent or gasoline ‘to wash them. * Apply brake fluid to the caliper bore and piston to be in- serted into the bore. Specification and classification; DOT4 CALIPER BOLTS © Tighten each bolt to the specified torque, Tightening torque Front brake caliper mounting bolt @:.20—30 N-m (2.0=3.0 kg-m, 14.5—21.5 tb-ft) Pads mounting bolt @ + 15-20 Nem (1.5=2.0 kg-m, 11.0-14.5 Ib-ft) Brake hose union boit!@ — : 15—20 Nem (1,.5-2.0 kg-m, 11.0—14.5 lb-ft) CAUTION: Bleed air {rom the system after reassembling the caliper. (Refer to page 2-16.) NOTE: Before rerpounting the caliper, push the piston all the way into the caliper.TO: 18478730197 PS DISC SERVICING * Remove the front and rear wheels. (Refer to pages 7-7 and 7-41.) G + Remove the disc. (Refer to pages 7-8 and 7-43.) « Install the disc. (Refer to pages 7-9 and 7-45.) DISC INSPECTION Using a micrometer, check the disc for wear, its thickness can be checked with disc and wheel in place. The service limits for the thickness of the discs are shown below. 09900-20205: Micrometer (0-25 mm) Service Limit (Front); 4.0 mm (0.16 in) (Rear) ; 4.5 mm (0.18 in) With the dise mounted on the wheel, check the disc for face runout with a dial gauge, as shown. 09900-20606: Dial gauge (1/100 mm) 09900-20701: Magnetic stand Service Limit: 0.30 mm (0.012 in) MASTER CYLINDER REMOVAL AND DISASSEMBLY 1. Disconnect the front brake light switch lead wires. 2, Place a rag underneath the union bolt on the master cylinder to catch any spilled drops of brake fluid. Remove the union bolt and disconnect the brake hose/ master cylinder joint, CAUTION: Immediately and completely wipe off any brake fluid con- tacting any part of the motorcycle. The fluid reacts chemi- cally with paint, plastics and rubber materials, ete. and will damage them severely.TO: 18478730197 P:6 3. Remove the master cylinder assembly. 4. Remove the front brake lever, reservoir cap and di- aphragm. 5. Drain brake fluid. 6. Remove the dust s the special tool. 1, then remove the circlip by using 09900-06108: Snap ring pliers 7. Remove the piston/secondary cup, primary cup and spring. @ Secondary cup @ Piston @ Primary cup @ 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 damage. Inspect the primary cup, secondary cup and dust seal for ‘wear or damage.CHASSIS TO: 18478730197 MASTER CYLINDER REASSEMBLY AND REMOUNTING Reassemble the master cylinder in the reverse order of removal and disassembly. Pay attention to the following points: CAUTION: * Wash the master cylinder components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to wash thom. * Apply brake fluid to the cylinder bore and all the compo- nent to be inserted into the bore. Specification and classification: DOT4 ‘© When remounting the master cylinder on the handlebar, align the master cylinder holder's mating surface © with punched mark @) on the handlebar and tighten the upper clamp bolt first as shown. Tightening torque: 8-12 N-m (0.8—1.2 kg-m, 6.0—8.5 Ib-ft) CAUTION: Bleed air from the system after reassembling master cylinder. (Refer to page 2-16.) Master cylinder HandlebarTO: 18478730197 PB CHASSIS 7. FRONT FORK ‘Tightening torque tem |__ Nem kgm Toft @ [30-40 | 3.0-4.0 [21.5—29.0 @ _| 18-28 | 18-28 ]13.0-20.0 ® 48-27 | 1,8-2.7 |13.0—19.5 “T1942: Apply THREAD LOCK "1342". REMOVAL AND DISASSEMBLY 1. Remove the cowling. (Refer to page 7-2.) 2, Remove the front wheel. (Refer to page 7-7.) 3, Remove the front fender brace with front fender by removing the fender brace mounting bolts. 4, Remove the brake hose clamps from the front fork.MAY-25-2082 @2:@3P FROM: TO: 18478730197 25 CHASSIS. 6. Remove the front fork after loosening the front fork up- per and lower clamp bolts. NOTE: ‘Slightly loosen the front fork cap bolt to facilitate later dis ‘assembly before loosening the front fork lower clamp bolts. 7. Remove the fork cap bolt, spacer, washer end spring. 8. Invert the fork and stroke it several times to let out fork oil, Under the inverted condition of front fork, drain oll to hold it for few minutes. 9. Remove the damper rod bolt with the special tools and 6-mm hexagon wrench. 09940-34520: ‘T” handle 09940-34561: Attachment 10. Remove the damper rod with spiMAY-25-2082 @2:@3P FROM: TO: 18478730197 11, Remove the dust seal © and stopper ring @. 12, Remove the oil seal by slowly pulling out the inner tube. NOTE: GA Be careful not to damage the inside of the tube. CAUTION: ‘The outer tube and inner tube “ANTI-FRICTION” metals must be replaced siong with oil seal and dust seal, when assembling the front fork. 13. Remove the spring adjuster @ from the fork cap @ by removing the clip. INSPECTION FORK SPRING Measure the fork spring free length. If it is shorter than the service limit, replace it with a new one. _ = Service Limit: 390 mm (15.4 in) INNER AND OUTER TUBE Inspect the inner tube sliding surface and outer tube sliding surface for any scuffing.7.27_CHASSIS eR CHAS SS DAMPER ROD RING Inspect the damper rod ring for wear or damage. REASSEMBLY AND REMOUNTING Reassemble and remount the front fork in the reverse order of removal and disassembly. Pay attention to the following poinits: ‘TUBE METALS AND SEALS ‘* Hold the inner tube vertically and clean the metal groove and install the ANTI-FRICTION metal by hand as shown. * Install the outer tube metal @) , washer @) and oil seal @ with the special tool. 09940-60113: Front fork oil seal installer CAUTION: Use special care to prevent damage to the “Teflon” coat- ed surface of the Anti-friction inner tube metal when mount- * Install the oil seal stopper ring @ . CAUTION: Make sure that the oil seal stopper ring fitted securely. + Install the dust seal @. DAMPER ROD BOLT Apply THREAD LOCK ‘1342” to the damper rod bolt and tighten it to the specified torque with a 6-mm hexagon wrench and special tools. 99000-32050: THREAD LOCK “1342” Tightening torque: 18--27 N-m (1.8-2.7 kg-m, 13.0-19.5 lb-ft) 09940-34520: ““T"" handle 09940-34561: Attachment “D”” TO: 18478730197 ‘THREAD LOCK "1342"MAY-25-2082 @2:@4P FROM: TO: 18478730197 CHASSIS 7.28 FORK OIL * Pour specified fork oil into the inner tube. Fork oil type: Fork oil #10 99000-99044-10G: SUZUKI FORK OIL #10 Capacity (each leg): 503 mi (17.0/17.7 US/imp oz) + Hold the front fork vertical and adjust the fork oil level with the special tool. 09943-74111: Fork oil level gauge Oil level: 92 mm (3.6 in) Note: When adjusting the oil level, remove the fork spring and com- press the inner tube fully. * When remounting the front fork assembly, set the upper surface of the inner tube at 22 mm (0.87 in) height from s the upper surface of the steering stem upper bracket. + Tighten the bolts to the specified torque. @ Fork lower clamp bolt ~ @ Fork cop 30-40 | 30—4.0 |21.6—29.0) @ Fork upper clamp bolt Ibe kg 18-28 | 1.8-2.8 |13.0-20.0 18-28 | 1.8-2.8 |13.0-20.0TO: 18478730197 P13 2_CHASSIS. SUSPENSION SETTING After installing the front fork, adjust the spring pre-load as. follows. SPRING PRE-LOAD ADJUSTMENT There are four grooved lines on the side of the spring ad- juster. Position 1 provides the maximum spring pre-load and position 4 provides the minimum spring pre-load. 2 4 ene — FRONT SUSPENSION SETTING (STD) ‘Spring pre-road 4 fs Dual riding a WARNING: Be sure to adjust the spring preload on both front fork legs ‘equally.TO: 18478730197 P14 cuassis_7.30 STEERING G: Apply SUZUKI SUPER GREASE Tightening torque Tem [Nm kom be @_|_80—100 | 8.0--10.0|58.0—72.5 @ | 22~35 | 2273.5 |16.0-26.5 @ | 18-28 | 18-28 [13.0200 @ [| 18-28 | 18-28 [130-200 REMOVAL AND DISASSEMBLY 1, Remove the cowling and cowling bra 72) 2. Remove the front wheel. (Refer to page 7-7.) 3, Remove the front fork. (Refer to page 7-24.) 4, Remove the front brake master cylinder with brake calipers. (Refer to page 8. Remove the handlebar mounting nuts and bolts after removing the bolt caps.MAY-25-2082 @2:@9P FROM: TO: 18478730197 P:1723 7.31_CHASSIS. 6. Disconnect the ignition switch lead wire coupler. 7, Remove the steering stem upper bracket by removing ‘the nut. 8. Remove the steering stem nut with the special tool. 09940-14911: Steering stem nut wrench 9. Draw out the steering stem lower bracket. NOTE: Hold the steering stem lower bracket by hand to prevent it from falling. 10. Remove the steering stem upper bearing. INSPECTION Inspect the removed parts for the following abnormalities. * Handlebar distortion ‘+ Race wear and brinelling + Bearing wear or damage * Abnormal noise of bearing * Distortion of steering stem DISASSEMBLY 1. Remove the steering stem lower bes I tool. 09941-84510: Bearing remover CAUTION: ‘The removed bearing should be replaced with a new one. 2. Drive out the steering stem bearing races, upper and low- er, by using the special tools. 09941-54911: Beating outer race remover 09941-74910: Steering bearing installerMAY-25-2082 2: 10P FROM: TO: 18478730197 Pree3, CHASSIS 7.32 REASSEMBLY AND REMOUNTING Reassemble and remount the steering stem in the reverse order of removal and disassembly. Pay attention to the fol- lowing points: OUTER RACES * Press in the upper and lower outer races by using the spe- cial tool. 09941-34513: Steering outer race installer BEARING * Place a suitable washer onto the lower bearing and press in the lower bearing by using the special tool. 09941-74910: Steering bearing installer ‘+ Apply grease to the upper and lower bearings before re- mounting the steering stem. 99000-25030: SUZUKI SUPER GREASE “A”” ‘STEM NUT * Tighten the steering stem nut to the specified torque. 09940-14911: Steering stem nut wrench Tightening torque: 40—80 N-m (4.05.0 kg-m, 29.0—36.0 Ib-ft) * Turn the steering stem lower bracket about five or six times to the left and right so that the taper roller bearing will be seated properly. + Turn back the stem nut by 1/4—1/2 turn, NOTE: This adjustment will vary from motorcycle to motorcycle. 4112 turnMAY-25-2082 2: 10P FROM: TO: 18478730197 P3723 7.33 CHASSIS * Install the front forks. (Refer to page 7-29.) * Tighten the front fork lower clamp bolts @), steering stem head nut @ , upper clamp bolts @ , handlebar holder mounting bolts @ and nuts © - Tightening torque Front fork lower =: 18—28 N-m clamp bolt © (1.8—2.8 kg-m, 13.0—20.0 Ib-ft) ‘Stem head nut @) : 80-100 N-m {8,0~ 10.0 kg-m, 58.0—72.5 lb-ft) Front fork upper }8—28 Nem clamp bolt (3) (1.8—2.8 kg-m, 13.0—20.0 Ib-ft) Handlebar holder =: 22—35 N-m mounting bolt @) (2.2-3.5 kg-m, 16.0—25.5 lb-ft) and nut © STEERING TENSION ADJUSTMENT Check the steering movement in the following procedure. ‘+ By supporting the motorcycle with a Jack, lift the front wheel until it is off the floor by 20—30 mm (0.8—1.2 in). * Check to make sure that the cables end wire hamesses are properly routed. ‘* With the front wheel in the straight ahead state, hitch the spring scale (special tool) on one handlebar grip end as ‘shown in the figure and read the graduation when the han- dlebar starts moving. Do the same on the other grip end. Initial force: 200-500 grams 09940-92710: Spring scale « If the initial force read on the scale when the handlebar starts turning is either too heavy or too light. adjust it til it satisfies the specification. 1) First, loosen the front fork upper clamp bolts and steer- ing stem head nut, and then adjust the steering stem nut by loosening or tightening it. 2) Tighten the head nut and clamp bolts to the specified torque and re-check the initial force with the spring scale according to the previously described procedure. 3) If the initiat force is found within the specified range, adjustment has been completed. NOTE: Hold the front fork legs, move them back and forth and make sure that the steering is not loose.MAY-25-2082 2: 10P FROM: TO: 18478730197 P:4723, cHaSSIS 7.34 IGNITION SWITCH * To remove the ignition switch, remove the bolt to detach the ignition switch from the steering stem upper bracket by using a center punch and hammer. HAMMER t PUNCH \ ‘* To install the ignition switch, always use the new spe- ences cial bolt and follow the procedures below: NOTE: The spare ignition switch comes equipped with the special bolts, however, the bolt is also individuelly available as a spare part. —, © Using the special bolts, attach the ignition switch on the steering etem upper bracket in place and run in the bolts with the special tool. TORK WRENCH 09930-11910: Torx wrench yo sur * Continue turning the tool until the too! slips from the bolt cour head or the bolt head breaks off, then the bolt has be- come tightened to the proper specification.MAY-25-2082 @2:11P FROM: TO: 18478730197 P:5723, 735 CHASSIS REAR BRAKE BRAKE PAD REPLACEMENT 1, Remove the dust cover.AP FROM: TO: 18478730197 P:6723 cuassis 2, Remove the clip © - 3. Draw out the pins @ and removing the springs @ . 4, Remove the pads @ and shims © . CAUTION: * Do not operate the brake pedal while dismounting the pads. * Replace the brake pad as a set, otherwise braking per- formance will be adversely affected. 5. Remount the new brake pads and fit the springs, pins and clip. CAUTION: Be sure to install the shims © properly as shown in the lustration. CALIPER REMOVAL AND DISASSEMBLY 1, Remove the union bolt @ and catch the brake fluid in @ suitable receptacle. CAUTION: Never reuse the brake fluld left over from previous servie- ing and stored for long periods. WARNIN 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 leakagi 2. Remove the caliper mounting bolts ® . NOTE: Slightly loosen the caliper housing bolts © to facilitate later disassembly before removing the caliper mounting bolts. 3. Remove the pads. 4, Remove the caliper housing bolts © .MAY-25-2082 @2:11P FROM: TO: 18478730197 P:7723, 7.37_CHASSIS. 5. Separate the caliper halves. 6. Remove the O-ring @ . NOTE: Once separate the caliper halves, replace the O-ring with a new one. 7. Place a rag over the piston to prevent it from popping out and push out the piston by using an air gun. cauTioN: Do not use high pressure air to prevent piston damage. 8. Remove the pistons. 9. Remove the dust seals and piston seals. CALIPER INSPECTION CYLINDER .... PISTON .. AUBBER PARTS . DISC v.ssscssesesessvees . Refer to page 7-20. . Refer to page 7-20. . Refer to page 7-20. . Refer to page 7-21.AP FROM: TO: 18478730197 CALIPER REASSEMBLY AND REMOUNTING Reassemble and remount the caliper in the reverse order of removal and disassembly. Pay attention to the following points: CAUTION: = Wash the caliper components with fresh brake fluid before reassembly. Never use cleaning solvent or gaso- fine to wash them. * Apply brake fluid to the caliper bore and piston to be in- serted into the bore. Specification and classification: DOT4 « Tighten each bolt to the specified torque. Tightening torque Rear brake caliper housing bolt © : 30—36 Nem (3.0—3.6 kg-m, 21.5—26.0 lb-ft) Rear brake caliper mounting bolt @ : 20-30 Nm (2.0—3.0 kg-m, 14.5=21.5 Ib-ft) Brake hose bolt @ : 15-20 N-m (1,5—2.0 kg-m, 11.0-14.5 Ib-ft) CAUTION: Bleed air from the system after reassembling the caliper. (Refer to page 2-16.) MASTER CYLINDER REMOVAL AND DISASSEMBLY 1, Remove both seats. 2. Remove the frame cover. (Refer to page 7-5.) 3. Free the reservoir tank to remove its mounting bolt © . 4. Loosen the lock nut © . $. Remove the master cylinder mounting bolts © . NOTE: ‘Slightly loosen the brake hose union bolt to fecilitate later disassembly before removing the master cylinder. 6. Place a cloth underneath the union bolt D on the master cylinder to catch spilled drops of brake fluid, 7. Loosen the union bolt and disconnect the brake hose from the master cylinder joint. NOTE: Immediately and completely wipe off any brake fluid con- tacting any part of the motorcycle. The fluid reacts chemi- cally with paint, plastics and rubber materials, etc. and will damage them severely.TO: 18478730197 P:9723 7-39 CHASSIS. 8, Remove the connector by removil 9. Remove the O-ring D. 10. Pull out the dust seal then remove the citclip by using the special tool. 09900-06108: Snap ring pliers 11. Remove the push rod, piston/primary cup and spring. MASTER CYLINDER INSPECTION CYLINDER, PISTON AND CUP SET © Inspect the cylinder bore walll for any scratches or other damage. © Inspect the piston surface for any scratches or other damage. * Inspect the cup set and each rubber part for damage.TO: 18478730197 P:10/723 CHASSIS 7-40 MASTER CYLINDER REASSEMBLY AND REMOUNTING Reassemble and remount the master cylinder in the reverse order of removal and disassembly. Pay attention to the fol- lowing points: CAUTION: * Wash the master cylinder components with fresh brake fluid before roassembly. Never use cleaning solvent or gasoline to wash them. * Apply brake fluid to the cylinder bore and all the compo- nent to be inserted into the bore. Specification and classification: DOT4 MASTER CYLINDER BOLTS * Tighten each bolt to the specified torque. Tightening torque Brake hose union bot — @: 15-20 N-m (1.5—2.0 kg-m, 11.0—14.5 lb-ft) Master cylinder mounting bolt @) : 18-28 Nem {1.8—2.8 kg-m, 13,0—20.0 Ib-ft) Master cylinder tod lock nut ©: 15-20 N-m (1.5=2.0 kgm, 11.0—14.5 Ib-ft) CAUTION: Bleed air from the system after reassembling master cylinder. (Refer to page 2-16.)MAY-25-2002 @2:12P FROM: P:11723 7.81_CHASSIS. REAR WHEEL ‘Th}360: Apply THREAD LOCK SUPER (eG "4380", _: SUZUKI SUPER GREASE "A". Tightening torque TEM [__ Nem kg-m Toot @ [18-28 [18-28 [13.0-200) @ [| 48-72 | 4.8-7.2 [38.0-52.0 @ | 85-115 | 85—11.5[61.5-23.0 REMOVAL AND DISASSEMBLY 1. Remove the lower cowling of rear. (Refer to page 7-2.) 2. Support the motorcycle with a jack. 3. Remove the axle cotter pin. 4. Remove the axle nut.MAY-25-2082 @2:13P FROM: TO: 18478730197 P1223 CHASSIS 7.82 5. Draw out the rear axle shaft. 6, Remove the rear wheel by disengaging the drive chain, CAUTION: ‘Do not operate the brake pedal while dismounting the brake caliper. 7. Draw out the rear sprocket mounting drum from the wheel. NOTE: Slightly loosen the reer sprocket mounting nuts to facilitate later disassembly before separate the mounting drum. 8. Separate the rear sprocket from the mounting drum. 9. Remove the spacer @ and dust seal @ . CAUTION: ‘The removed dust seal should be replaced with a new one, 10. Remove the drum retainer @ , draw out the sprocket mounting drum bearing @ using an appropriate tool. CAUTION: ‘The removed bearing should be replaced with a new one. 11, Remove the cushions.7-43_ CHASSIS TO: 18478730197 P:1323 12, Separate the brake disc from the wheel. INSPECTION AND DISASSEMBLY THRE Refer to page 7-12. WHEEL BEARINGS Inspect the play of the wheel bearings by hand while they ‘the wheel. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. Replace the bear- ing if there is anything unusual, CAUTION: The removed bearings should be ieplaced with new ones. AXLE SHAFT Using @ dial gauge, check the axle shaft for runout and replace it if the runout exceeds the limit. 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 checked as shown does not exceed the service limit. An excessive runout is usually due to worn or loose wheel bearings and can be reduced by replacing the bearings. If bearing replacement foils to reduce the runout, replace the wheel. Service Limit (Axial and Radial): 2.0 mm (0.08 in) Drive out the left and right wheel bearings with an appropri- ate steel bar. CAUTION: ‘The removed bearings should be replaced with new ones.TO: 18478730197 P:14723 CHASSIS_7.44 CUSHION Inspect the cushion for wear and damage. SPROCKET Inspect the sprocket teeth for wear. If they are worn as shown, replace the sprockets and drive chain as a set. REASSEMBLY AND REMOUNTING Reassemble and remount the rear wheel in the reverse ord- er of removal and disassembly. Pay attention to the follow- ing points WHEEL BEARING * Apply grease to the bearings before installing. 99000-25030: SUZUKI SUPER GREASE “A” © Install the wheel bearings by using the special tool. 09941-34513: Bearing installer set NOTE: First install the right whee! bearing, then install the left wheel bearing. The sealed cover on the bearing is positioned out- side, Refer to page 7-45 for details. Normal wear Excessive wearTO: 18478730197 P:15723 Lefega = Right Lett = =D Right ( MOUNTING DRUM BEARING © Install the bearing by using the bearing installer. 09913-76520: Bearing instal NOTE: Apply grease to the bearing and oil seal lip before assem- bling rear wheel. BRAKE DISC * Apply THREAD LOCK SUPER ‘"1860" to the disc bolts and tighten them to the specified torque. NOTE: Make sure that the brake disc is clean and free of any greasy matter. 99000-32130: THREAD LOCK SUPER “1360 disc bolt: 18-28 N-m (1.8-2.8 kg-m, 13.0~20.0 lb-ft) BrabMAY-25-2082 @2:14P FROM: TO: 18478730197 16723, CHASSIS. 7.46 REAR SPROCKET * Tighten the sprocket mounting nuts to the specified torque. Rear sprocket nut: 48—72 N-m (4.87.2 kg-m, 35.0—52.0 lb-ft) NOTE: Face the stamped mark on the sprocket to outside. REAR AXLE SHAFT ‘« Adjust the chain slack after rear wheel installation. (Refer % Ea) to page 2-12.) ‘* Tighten the rear axle nut to the specified torque. * Tighten both chain adjuster bolts securely. Rear axle nut: 85-115 N-m {8.5—-11.5 kg-m, 61.5—83.0 lb-ft) ; [ cjea Mata (Grease) 615-830 be 20-30 Nm e532 '3,) 14.5—21.8 Ibe ) th1360 18.0-28.0 Nm ol tg528'9e,) 13.0~20.0 thet (ioe En Th1380: Apply THREAD LOCK SUPER. ioe G = Apply SUZUKI SUPER GREASE "MAY-25-2082 @2:14P FROM: 7-47_CHASSIS, TO: 18478730197 P:17723 REAR SUSPENSION SWINGARM, SHOCK ABSORBER AND CUSHION LEVER Tightening torque Tew [Nm kom ibe @ | 25-115 | 8.5—11.5/61.5-83.0 @ | 40-60 | 4.0-6.0 |29.0-43.5 @_| 70—100 | 7.0-10.0|50.5—72.5 G: Apply SUZUKI SUPER GREASE “A”TO: 18478730197 P:18723 CHASSIS 7.48 REMOVAL 1, Remove the seats and frame covers. (Refer to page 7-6.) 2. Remove the rear wheel. (Refer to page 7-41.) 3, Remove the rear brake hose union bolt. CAUTION: Completely wipe off any brake fluid adhering to any part of motorcycle. The fluid reacts chemically with paint, plastics, rubber materials, etc. 4. Remove the brake hose from the brake hose guides at inside of swingarm. 5. Remove the chain case. 6. Remove the shock absorber upper mounting nut and bolt. 7. Remove the cushion lever mounting nut and bolt. 8. Remove the caps. 9. Remove the swingarm pivot shaft by removing the pivot shaft nut. 10. Remove the rear suspension assembly.MAY-25-2082 2: 15P FROM: TO: 18478730197 P:19723 7.49 CHASSIS 11. Remove the cushion rod mounting nut and bolt. 12. Remove the chain buffer. 13. Remove the spacers from swingarm. 14, Remove the rear shock absorber and cushion rods. 18. Remove the cushion lever spacers.MAY-25-2082 2: 15P FROM: TO: 18478730197 P2023 cHassis_7.50 INSPECTION AND DISASSEMBLY : SWINGARM Inspect the spacer for any flaws or other damage. Inspect the swingarm for wear or damage. Insert the spacer into bearing and check the play to move ‘the spacer up and down. If excessive play is noted, replace the bearing with a new one, Draw out the swingarm bearings with the special tool. 09941-44510: Swingarm bearing remover CAUTION ‘The removed bearings should be replaced with new ones. CUSHION LEVER Inspect the spacer for any flaws or other damage. Insert the spacer into bearing and check the play to move the spacer up and down. If an excessive play is noted, replace the bearing with a new one. Draw out the bearing with the special tools. 09923-73210: Bearing puller 09930-30102: Sliding shaft CAUTION: ‘The removed bearings shauld be replaced with new ones. ‘SHOCK ABSORBER Inspect the shock absorber body for damage and oil leak- age. If any defects are found, replace the shock absorber with new one. CAUTION: Do not attempt to disassemble the rear shock absorber unit. tt is unserviceableMAY-25-2082 2: 16P FROM: TO: 18478730197 P:21723 7.51_CHASSIS SWINGARM PIVOT SHAFT Using a dial gauge, check the pivot shaft runout and replace it if the runout exceeds the limit. (09900-20606: Dial gauge (1/100 mm, 10 mm) 09900-20701: Magnetic stand 09900-21304; V-block (100 mm) Service Limit: 0.3 mm (0.01 in) CHAIN BUFFER Inspect the chain buffer for wear and damage. If any defects are found, replace the chain buffer with anew one. REASSEMBLY AND REMOUNTING Reassemble and remount the swingarm and shock absorb- er in the reverse order of removal and disassembly, and also carry out the following steps: SWINGARM BEARING * Press the bearing into the swingarm pivot by using the special tool. 09941-34513: Steering race installer NOTE: When reinstalling the bearing, stamped mark of bearing is positioned outside '* Apply grease to the spacers and bearings. 99000-25030: SUZUKI SUPER GREASE “A”MAY-25-2082 2: 16P FROM: TO: 18478730197 P:22723 CHASSIS_7.52 REASSEMBLY ONTO FRAME «First of all assemble the shock absorber, cushion lever and cushion rods onto the swingarm. Lett side-<— ? Ges en) Tightening torque 49-60 Nem (2588 0n,,) Tightening torque 23.0-~43.5 bt Tightening torque 70100 Nem = 10.0 Kam ) \80.5—72.5 Ibe Tightening torque 70—-100N-m (Z85 19.9 kom 50.5 72.5 Ib © Tightening torque 85-118 N-m (255145 i0m) 61.5—93.0 Ibe Te too Nm 0g) e928 bm © — E G: Apply SUZUKI SUPER GREASE “A”.TO: 18478730197 P:23/23 7-53_ CHASSIS 7-83 CHASSIS FINAL INSPECTION AND ADJUSTMENT After installing the rear suspension and wheel, the follow- ing adjustments are required before driving. * Drive chain * Rear brake * Tire pressure * Chassis bolts and nuts * Shock absorber SUSPENSION SETTING After instelling the rear suspension, adjust the spring pre- load and rebound damping force as follows. REBOUND DAMPING FORCE ADJUSTMENT The set position “4” provides the stiffest rebound damp- ing force. The set position ‘“1’” provides the softest rebound damp- ing force. (STD position: 2”) SPRING PRE-LOAD ADJUSTMENT The set position ’7" provides the stiffest spring pre-load. The set position ‘'1"” provides the softest spring pre-load. "3"1 REAR SUSPENSION SETTING Hem ‘Spring set position | Damping force (Rebound) Softer 2 7 Solo riding ‘Standard 3 2 Stiffer 4 3 Dual riding 4 4SERVICING INFORMATION CONTENTS TROUBLESHOOTING oo a7 WIRING DIAGRAM WIRE HARNESS, CABLE AND HOSE ROUTING - B12 COWLING AND FRAME COVER SET UP ~ “+ 8-23 8-26 8-29 8-32 SPECIAL TOOLS « TIGHTENING TORQUE SERVICE DATA PiaMAY-25-2082 2: 18P FROM: 1_SERVIGING INFORMATION TO: 18478730197 P17 TROUBLESHOOTING : ENGINE Complaint Symptom and possible causes Remedy Engine will not start, | Compression too low or is hard to start. | 1. Out of adjustment valve clearance. Adjust. 2. Worn valve guides or poor seating of valves. Repair or replace. 3. Mistiming valves. Adjust. 4. Excessively worn Replace. 5. Worn-down cylinder bores. Replace or rebore. 6. Too slowly starter motor cranks. See electrical section, 7. Poor seating of spark plugs. Plugs not sparking 1, Fouled spark plugs. 2. Wet spark plugs. 3. Defective Ignition coi 4. Open or short in high-tension cords. 5. Defective signal generator or ignitor unit. No fuel reaching the carburetors 1. Clogged fuel tank vent hose. 2, Clogged or defective fuel/cook. Clean or replace. Clean or replace. Clean or replace. Engine stalls easily. Noisy engine. 3. Defective fuel pump or ignitor unit. Replace. 4, Defective carburetor needle valve. Replace. 5, Clogged fuel hose or fuel filter. 1. Fouled spark plugs. Clean, 2. Defective signal generator or ignitor unit, Replace. 3. Clogged fuel hose. Clean. 4. Clogged jots in carburetors. Clean. 5. Out of adjustment valve clearance. Adjust. Excessive valve chatter 1. Too large valve clearance. Adjust 2. Weakened or broken valve springs. Replace. 3. Worn tappet or camsurface. Replace. 4. Worn and burnt camshaft journ Noise seems to come from piston 1. Worn down pistons or cylinders. 2. Fouled with carbon combustion chambers. Replace. 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. 3, Not working tension adjuster. Noise seems to come from clutch 1. Worn splines of countershaft or hub. Replace 2. Worn teeth of clutch plates. Replace. 3. Distorted clutch plates, driven and drive, Replace. 4. Worn clutch release bearing. Replace. 5. Weakened clutch dampers. > Repair or replace. Replace the primary driven gear.SERVICING INFORMATION 2 ‘Symptom and possible causes Remedy Noise soems to come from crankshaft 1, Due to wear rattling bearings. Replace. 2. Worn and burt big-end bearings. Replace. 3, Worn and burt journal bearings. Replace. 4. Too large thrust clearance. Noise seems to come from transmission Replace thrust bearing. 1. Worn 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 shatt 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. 1. Out of adjustment or too much play clutch control. | Adjust. 2. Some clutch springs 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 pawl. Replace. Transmission will 1, Broken return spring on shift shaft, Replace. not shift back. 2. Rubbing or stickly shift shaft Repair or replace. 3. Distorted or worn gearshift forks. Replace. Transmission jumps | 1. Worn shifting gears on driveshaft or countershaft. | Replace. ‘out of gear. 2. Distorted or worn gearshift forks. Replace, 3. Weakened stopper spring on gearshift stopper Replace. 4. Worn gearshift pawl. Replace. Engine idles poorly. | 1. Qut of adjustment valve cl Adjust. 2. Poor seating of valves Replace or repair. 3. Defective valve guides. Replace. 4. Worn tappet or camsurfac Replace, 8. Too wide spark plug gaps. Adjust or replace. 6. Defective ignition coll. Replace, 7. Defective signal generator or ignitor unit Replace, 8, Out of adjustment in carburetors float-chamber | Adjust. fuel level 9. Clogged jets or imbalance of carburetors. 10. Defective fuel pump oF ignitor unit. Clean or adjust. Replace.MAY-25-2082 @2:19P FROM: TO: 18478730197 PT 8.3 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 timing out of adjustment. Adjust. 4. Too narrow spark plug geps Adjust. 5. Ignition not advanced sufficiently due to poorly | Replace ignitor unit. working timing advance circuit. Replace. Defective signal generetor or ignitor unit. Replace. Clogged air cleaner element. Clogged fuel hose, resulting in inadequate fuel supply to carburetors, 11. Detective fuel pump or ignitor unit. 6. 7 8, Too low float-chamber fuel level 9. 0. Clean and prime. Replace. Dirty or heavy exhaust smoke 1. Too much engine oil in the engine. Check with inspection window drain out excess oil. 2. Wom piston rings or cylinders. Repla 3. Worn valve guides. Replace. 4, Scored or soutfed cylinder walls. Rebore or replace. 5. Wom valves stems. Replace, 6. Defective stem seal. Replace. 7. Worn oil ring side rails. Replace. Engine tacks power. | 1. Loss of vaive clearance Adjust. 2. Weakened valve springs. Replace. 3. Out of adjustment vaive timing. Adjust. 4. Worn piston rings or cylinders. Replace. 5. Poor seating of valves. Repai 6. 7. 8. |. Fouled spark plug. / Incorrect spark plug. . Clogged jets in carburetors. 9. Out of adjustment flost-chamber fuel level. 10. Clogged air cleaner element. 11. Loose carburetor balancing screw. 12. Sucking air from intake pipe. 13. Too much engine oil, Clean or replace. Adjust or replace. Clean. Adjust. Clean. Retighten, Retighten or replace. Drain out excess oll. 14. Detective fuel pump or ignitor unit. Replace, Engine overheats. 1. Heavy carbon deposit on piston crowns, 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 fue! level. Adjust. 5. Sucking air from intake pipes. Retighten or replace. 6. Use incorrect engine oi Change. 7. Defective cooling system. See radiator section.MAY-25-2082 @2:19P FROM: TO: 18478730197 P47 SERVICING INFORMATION 6.4 RADIATOR Complaint Symptom and possible causes Remedy 1. Not enough cooling water. ‘Add coolant. 2. Clogged with dirt or trashes radiator core, Clean. 4. Erratic thermostat, stuck in closed position. Roplace. 4, Fouity cooling fan. Repair or replace. 5, Defective thermo-switch. Replace. 8. Clogged water passage. Clean, 7. Air trapped in the cooling circuit. Bleed ut air. 8. Defective water pump. Replace 8. Use incorrect coolant. Replace. Engine overcools. | 1. Erratic thermostat, stuck in full-open position. | Replace. 2. Defective thermo-switch, Replace, 3. Extromely cold weather. Put on the radiator cover. CARBURETOR Comptaine ‘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 and | Check starter body and carburetor. carburetor for tightness, adjust and replace gasket. 4. Air leaking from carburetor’s joint or vacuum Check and adjust. gauge joint. 5, Not operation properly starter plunger. Check and adjust. Idling or low-speed | 1. Clogged or loose pitot jet. pilot ai Check and clean. trouble. 2. Air leaking from carburetor’s joint, vacuurn gauge | Check and adjust, joint, or starter. Clogged pilot outlet or bypass. Not fully closed starter plunger. Medium-or high speed trouble. a epelae Check and clean. Check and adjust. . Clogged main jet or main air jet. . Clogged needle je . Not operating properly throttle valve. . Clogged fuel filter. ‘Overfiow and fuel level fluctuations easenn Check and clean. Check and clean Check throttle valve for operation. Check and clean. ‘Worn or damaged needle vaive. Broken spring in needle valve. Not working property float. Foreign matter has adhered to needle valve. . Too high or low fuel level, . Defective fuel pump or ignitor unit. Roplace. Replace, Check and adjust. Clean. Adjust float height. Replace.MAY-25-2082 @2:19P FROM: TO: 18478730197 PST ELECTRICAL Complaint ‘Symptom and possible causes Remedy No sparking or poor | 1. Defective ignition coil. Replace. sparking. 2, Detective spark plugs. Replace. 3. Defective signal generator or ignitor unit. Replace. Spark plug soon 1, Mixture t00 rich. Adjust carburetors, become fouled with | 2. Idling speed set to high. ‘Adjust carburetors. carbon, 3. Incorrect gasoline. Change, 4, Dirty element in air cleaner. Clean. 5. Too cold spark plugs. Replace with hot type plugs. ‘Spark plugs become fouled too soon, Worn piston rings. Worn piston or cylinders. Excessive clearance of valve stems in valve guides. Worn stem oil seal, Replace. Replace, Replace. Replace. ‘Spark plug electrod- 3 overheat or burn, pon Too hot spark plugs. . Overheated the engine. . Loose spark plugs. . Too lean mixture, Replace with cold type plugs. Tune up. Retighten. Adjust carburetors, Generator does not charge. « Open or short lead wires, or loose lead connections. 2. Shorted, grounded or open generator colls. » . Shorted or panctured regulator/rectifiers. Repair or replace or retighten, Replace. Replace. Generator does charge, but charging Lead wires tend to get shorted or open-circuited or loosely connected at terminals. Repair or retighten. rate is below the 2. Grounded or open-circuited stator coils or Replace. specification. generator. 3. Defective reguiatorirectiier. Replace. 4. Defective cell plates in the battery. Replace the battery. Generator 1. Internat short-circuit in the battery. Replace the battery. overcharges. 2. Damaged or defective resistor element in the Replace. regulator/rectifier. . Poorly grounded regulatorirectifier. Clean and tighten ground connection. Unstable charging. ey Lead wire insulation frayed due to vibration, resulting in intermittent shorting. . Internally shorted generator. }. Defective regulator/rectifier. Repair or replace. Replace. Replace. Starter button is not effective. ere Run down battery. Defective switch contacts. . Not seating properly brushes on commutator in starter motor. Defective starter relay/starter interlock switch, Repair or replace. Replace. Repair. or replace. Replace.MAY-25-2082 @2:20P FROM: TO: 18478730197 P67 SERVICING SEC INFORMATION. 8.6 BATTERY Complaint Romedy “Sulfation”, acidic white powdery sub- stance or spots on Symptom and possible causes mi 1. Cracked battery case. 2. Battery has been left In a run-down condition for a long time. Replace the battery. Replece the battery. 2. Cell plates have lost much of their active material as a result of overcharging, 3. A short-circuit condition e» 4, Too low battery voltag within the battery. 5. Too old battery. surfaces of cell Plates. Battery runs down | 1. Not correct the charging system. Check the genorator, quickly, regulator/rectifier ana circuit connections and make necessary adjust- ments to obtain specifi ed charging operation Replace the battery, and correct the charg- ing system. Replace the bettery. Recharge the battery fully. Replace the battery. Battery “sulfation”, 1. Too low or too high charging rate. (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 climate. Replace the battery. Replace the battery, if badly sulfated. Battery discharges too rapidly. Diy container top and sides. Clean,MAY-25-2002 @2:20P FROM: TO: 18478730197 7_ SERVICING INFORMATION Pivey CHASSIS Complaint Symptom and possible causes Remedy Heavy steering, 1. Overtightened steering stem nut. Adjust. 2. Broken bearing in steering stem. Replace. 3. Distorted steering stem. Replace. 4. Not enough pressure in tires, Adjust. ‘Wobbly handlebars. | 1. Loss of balance between right and left front forks. | Replace. 2. Distorted front fork. Repair or replace. 3. Distorted front axle or crooked tire, Replace. Wobby front wheel. | 1. Distorted wheel rim. Replace. 2. Worn front wheel bearings, Replace. 3, Defective or incomect tire, Replace. 4. Loose axle. Retighten. 5. Incorrect front fork oil. Adju Front suspension 1. Weakened springs. Replace. t00 soft. 2, Not enough fork oil. Replenish. Front suspension 1. Teo viscous fork oil. Repla too stiff. 2. Too much fork oi Drain excess oil Noisy front 1. Not enough fork cil. Replenish. suspension, 2, Loose bolts on suspension. Retighten. Wobbly rear wheel. | 1, Distorted wheel rim. Replace. 2. Worn rear wheel bearing or swingarm bearings. | Replace. 3. Defective or incorrect tire: Replace. 4. Worn swingarm and rear cushion related bearings. } Replace. 5. Loose nuts of bolts on rear suspensions. Retighten. Rear suspension 1, Weakened shock absorber spring. Replace. too soft. 2. Improperly set rear suspension adjuster. Adjust. 3. Leakage oll 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 shat. Replace. 3. Bent ewingarm. Replace. 4. Worn swingarm and rear cushion related bearings. | Replace. Noisy rear 1, Loose nuts or bolts on rear suspension. Retighten. suspension. 2. Worn swingarm and rear cushion related bearings. | Replace. CoMAY-25-2082 @2:34P FROM: TO: 18478730197 Pia SERVICING INFORMATION 9-8 BRAKES ‘Complaiat ‘Symptom and possible causes Remedy Insufficient broke 1. Leakage of brake fluid from hydraulic system. Repair or replace. power. Worn pads. ‘Worn disc. 2, 3. Oil adhesion of engaging surface of pads. 4. 6. Air in hydraulic system. n disc and pads. Replace. Blead alr. Brake squeeking. 1. Carbon adhesion on pad surface. 2. Tiked pad. Damaged wheel bearing. Loosen front-wheel axle or 1 Foreign material in brake fluid. Clogged rotum port of master cylinder. 3. 4. 8. Worn pads. 6. 7 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 fever stroke. 1. Ait in hydraulic system. 2, Insufficient brake fluid. 2, Improper quality of brake fluid. Bleod air Replenish fluid to spe- ified level; bleed air. Replace with correct fluid. [Tearage of bake fluid. 1. Insufficient tightening of connection j 2. Cracked hose. 3. Wom piston and/or cup. Tighten to specified torque. Replace. Replace piston and/or cup.Pri74 TO: 18478730197 MAY-25-2082 @2:35P FROM: 89 SERVICING INFORMATION WIRING DIAGRAM For U.S.A. /Asooem rg si eBUDID. * ww U w ) Jeoen pou yuma sBueID * 28uei9 SYA s808n AOq@A Mm UODHD aBe0SSF0 am 38g YUM ang NO JA WA OBIE * “AO se0en OHUAK aE 081g 1¥O109 auIM t 1 —O Oe)Pia74 TO: 18478730197 MAY-25-2082 @2:35P FROM: For Australia Jaen poy Bim aBueig °° Ja0en poy wim yaeig * o8uei9 -** seo@n Usain yuMe oBueID °° uuoi8 wer * “ode anig usin @BUeIQ °° enya 16 soe yoeIg WpiM oBUEID Ae u uMo1g eng wos” i ‘80109 BHI. 7%Y & Ww UO v Jy so2en poy Yalan €8U2i0, o6u219 seoen woeip yim oBueI9 wooiB uEA * eng ayer 4219, 2915 yee YORI omorg 4998 MO|]8A MIM HOBIE” 19988 OY MIM DEI” YOTO aun 2 grease ous “HBS “BASS ET nace : mau G:11_ SERVICING INFORMATION MAY-25-2082 @2:36P FROM: For The othersTO: 18478730197 P44 SERVICING INFORMATION WIRE HARNESS, CABLE AND HOSE ROUTING WIRE HARNESS ROUTING ‘To the fast gauge Soma rlay cramo Clemo tame Stoner metor Hance Siena generator bore & pressure Swi / om Combination mete Secarates____ anerator come Revival raiestor Switch Signal generator Fe cane ‘Wiring Rerrese_| waing harness ‘gon ewer L ciome came Fring narness [wiring meres Front tun signal wiring nevness| —[Side-stand switch | Wing hemens oa idm [Battery Griead | Side-tond ew ich Postion GRE sre clame cums ek creme Clemo ine j Sj Hncieber switch tL load wire Hanoleber swlech (R) Tomecem toad wire Hanalever ewitch (R) & tL) combination light ae toma clare Wing narness Wiring nerness Side-stond swith 9 sice-standeeay |S 3 Handtabar switeh (0 Tum signal“ cA [Wing hemess riny 7 1 comp eee beak come renee ey clampMAY-25-2082 @2:47P FROM: TO: 18478730197 8-13. SERVICING INFORMATION. Oil pressure switch lead wire Generator’ Starter motor Be careful not to bite the lead wires between the crankcase and water pump | ‘case when installing the water pump.MAY-25-2002 @2:48P FROM: TO: 18478730197 Pri74 SERVICING INFORMATION 9.14 HIGH-TENSION CORD ROUTING Ignition coil No.1 & 4 Ignition coil No.2 & 3 Spark plug cap High-tension cord No.4 pe be r Clamp _High-tension cord No.2MAY-25-2002 82:49P FROM: TO: 18478730197 Prag 8.18, SERVICING INFORMATION CABLE ROUTING GS Engine coolant reservoir tank Pass through the throttle cables outside the brake hose. {returning cable) ‘Throttle cable (pulling cable) Throttle cable {returning cable) Engine cooiant ‘reservoir tank hose Cable guideMAY-25-2002 82:49P FROM: TO: 18478730197 P34 SERVICING INFORMATION 8.16 FUEL SYSTEM HOSE ROUTING Fuel hose Fuel pum [te 3 Q é ge ‘ Q Air vent hose, ih cs Fuel hose , LT Fugl cock Spacer j Cushion Breather hose Bott —< oy Spader aS Fuel tank water To fuel tank _ GUS) ten» Air cleaner drain hose Carburetor clamp position (Engine side) ‘OOO Carburetor clamp position (Air cleaner side)MAY-25-2082 @2:49P FROM: TO: 18478730197 P44 8-17_ SERVICING INFORMATION OIL HOSE ROUTING 7 fg. : 25 fee : 3 o 2 B20 es 72 § ie 58 SS Pes #8 af? bao 3 a? 3} a 3g = ae ae e z a OY 2 Pan &—ty = te $20 aa ge Sy a 2 2 Bs &2 £ z 33 g 2 28 i A £ Keep cleerance betwoon hose end cylinder head.MAY-25-2082 @3:@eP FROM: TO: 18478730197 Pit SERVICING INFORMATION 8-18 COOLING SYSTEM HOSE ROUTINGMAY-25-2082 @3:@eP FROM: 8.19 SERVICING INFORMATION TO: 18478730197 (6.3 kg-m, 42.7 Ibtt) PeMAY-25-2082 @3:@3P FROM: TO: 18478730197 P:3 SERVICING INFORMATION. 8.20 FRONT BRAKE HOSE ROUTING Brake hose Throttle cable!MAY-25-2082 @3:@3P FROM: TO: 18478730197 Pq B.21_ SERVICING INFORMATION REAR BRAKE HOSE ROUTING Clamp screw Reservoir tank After touching the brake hose union to the stopper, tighten the union bolt to the. specified torque. Master cylinder: Clamp Brake hose After touching the brake hose union to the stopper, tighten the union bolt to the, specified torque.MAY-25-2082 @3:@3P FROM: RY TO: 18478730197 PS PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING (For California model) ot I ES rama chomrron el) WS PAIR control valve No.2 hose PAIR controt valve No.2 hose PAIR reed valve No.1 hose PAIR reed valve PAIR air pipe PAIR air pipe No.2 No.4TO: 18478730197 MAY-25-2082 @3:@5P FROM: 8.23. SERVICING INFORMATION COWLING AND FRAME COVER SET UP COWLING SET UPMAY-25-2082 @3:@5P FROM: TO: 18478730197 Pe SERVICING INFORMATION 8.24 3 Service lid Rear lower cowiling (t) Service lid C : Unit: mn Reor fowor ‘cowling {R) Under panel fower/ e Att tower, 7 cowiing ¥ Under pane! e Right lower cowling cowling,MAY-25-2082 @3:@5P FROM: TO: 18478730197 P:3 8.25 SERVICING INFORMATION FRAME COVER SET UP LOWER COWLING CUSHION = ‘Cushion Cushion Cushion Unit mm CushionMAY-25-2082 @3:@5P FROM: SPECIAL TOOLS TO: 18478730197 Pq SERVICING INFORMATION 8.25 ~4 SA "ripe nexogon | o9a00-00810 | gssao.e10s | cas00.08107 | oas00-08108 ela Rexagonwrench set | Seapine plore [Sesser shon | $9800,08708 Ge, 990020202" | a9000-20203 | o9900-20208 e2s0020102 | taoomans formate Mcrmetr ceso00003 | Yaneruinre | Mrasosae neo, Mie08 Sr, fronct tree set _| WiBO ren 208 my | 2350 Soren) | Ose ma oasa020s00 09900-20808 Cylinder gauge set 09900-20602 Dial calipers: 09900-20606 BINGO ne ial geuse fineo mee Baie Pay CANGoC mm + mn) | $0 FA7tG0 a, 10 ros NY oxton 401 29900-20803 _| ov00-20805 7 200022301 | Sema gs Srisneas eae | Treen pegs | UG0'me Fintmage (ro et rezone © \ 9010-20116 yoctemgon | o9011-74820 cea ah ae pice (09913-60910 \ 09914-25811 oosis.1si21 | Senmpouter | 09012-75820 | ogoraZasro | °9°"syaboragon Gersustortancar | so Go'mmmt [pang tnsaner | Panes ee erMAY-25-2082 @3:@6P FROM: TO: 18478730197 PS 8.27 SERVICING INFORMATION 09916-74610 09916-64510 0 pressure gauge Compression gauge | 09918-77330 09016-74540 09915-40610 oggi6-63310 Wor high pressure | Oi pressure gouge | o9916-14510 Ointier wrench | (adaptor eter! adaptor Valve iter YN wy By iy > S00 poge 3-24, 09916-14520 09916-20640 Vatve seat cutter 09916-33210 Vaive titer attach. | Sold pilot, 09916-21110 head (W111, 118, | Valve guide veamer ment n-t00-4.5) Vaive seat cutar ont | 120, 121, 122.126) | (ab wen) A OQ SS 09016-34542 09016-34580 09916-43210 09916-74521 € Valve guide reamer | Valve guide reamer | Vaive guide remover! | 09916-43230 Piston ring com- handle (90.8 mm) inca ‘Anachmant pressor body Piston ting com- 09920-53740 09923-73210 prosoor bund osst6-24611 Clutch sleeve hub | Bearing puller 9926-24510 (63-75 mm) (17=20 mm Bearing netaor sot 09924-84521 09930-11910 09930-14530 (09930-20102 ( Bearing installer ‘Torx wrench Universal joint Suaing shart ‘S| eadsea] S| id cu 09931-94430 9940-14911 = 99940-50113 Ignitor checker | Steering stam mut | 09940-24520 o9e40-3661 Front fork of seal (Digital type) wrench oT" handle Attachment “D" __| installer‘SERVICING INFORMATION 8:28 & 09941-34513, 09941-44610 09941-54911 99940-92710 Steering outer race | Swingarm bearing | 09941-50111 Booting outer race Spring scale inetatler remover Bearing remover__| remover 99941-74910 09943-74111 Stooring bearing | 09941-84510 Front fork oil evel | 08951-16080 Ingtatier Bearing remover | gouge Bearing inetallor NOTE: When ordering the special tool, ples confirm whether it is available or not.MaY-25-2022 @3:06P FROM: TO: 18478730197 Pi? 25 SERVICING INFORMATION TIGHTENING TORQUE ENGINE TEM. Nm Weft Cylinder head cover bolt, 13-15 9.5—11.0 Cylinder head bolt [M: 101 40-45 29.0 32.5 Cylinder head bolt [M: 6] 8-12 6.0-8.5 Cylinder base nut 711 5.08.0 ‘Camshaft journal holder bolt e-12 6.08.5 ‘Cam sprocket bolt 24—26 17.5—19.0 Oil hose mounting bolt [Cylinder side) 20—23 14.5-16.5 il hose mounting bolt {Crankcase sidel 25-29 18.0—21.0 ‘Cam chain tensioner mounting bolt 6-8 456.0 ‘Cam chain tensioner spring holder bolt ‘30-40 21.5—29.0 ‘Conrod bearing cap bolt 65-68 47.0—49.0 Starter clutch bolt 23-28 16.5—20.0 ‘Signal generator bolt 23-26 16.5~19.0 Crankcase bolt (M: 6] 12=16 8.5—16.5 IM: 8] (M: 91 24-28 17.5—20.0 ‘Oil pump mounting bolt 6-12 6.08.5 Oil drain plug 20—25 14.5-18.0 ‘Oil pan bolt 12-16 85-115 [Gearshift cam stopper bolt 8-12 6.0—8.5 Gearshift cam stopper plate bolt B=12 6.0-8.5 Gearshift arm stopper bolt 15—23 71.0-16.5 ‘Clutch sleeve hub nut ‘80—100 58.0-72.5 ‘Clutch spring bolt 1113 8.09.5 Exhaust pipe bolt 18~28 13.0--20.0 Muffler mounting bolt 18-28 13.0-20.0 Engine sprocket nut 100-130 72.5—94.0 : 30) 50-60 36.0—43.5 (40 and 280) 70-88 50.5—63.5 Starter clutch shaft nut ‘80-100 68.0—72.6 Generator driven gear nut 40-60 29.0—43.5 Generator mounting bolt 21-29 16.0—21.0 Oil cooler mounting bolt 53-64 38.5—46.5 Oil pressure regulator 25-30 18.0-21.5 Ol pressure switch 12-15 8.5—11.0 Oil gallery plug [M: 16] 35-45 25.5—32.5 IM: 44] 25—30 18.0-21.5 IM: 10) 12-18 8.5—13.0 Crankcase plug [M: 22] 35—45 25.5—32.6 IM: 18) 25-30 18.0—21.5 Cooling fan thermo-switch 914 6.5—10.0TO: 18478730197 PB SERVICING INFORMATION CHASSIS (TEM Nem kg-m io-ft Steoring stem head nut ‘80-100 8.0-10.0 | 58.0—72.5 Front fork upper clamp bolt 16-28 1.8=2.8 | _13.0—20.0 Front fork lower clamp Bolt 16-28 71.8—-2.8 | 13.0-20.0 Front fork cap bolt 30-40 3.0—4.0 | 21,.5—29.0 Front fork damper rod bolt 18-27 18—2.7 | 13.0—-19.5 Front axle 50—80 5.0-8.0 | 36.0-58.0 Front axle pinch bolt 18-28 18-28 | 13.0-20,0 Handlebar set bolt 18-28 78-28 | 13.0-20.0 | Handlebar holder mounting bolt and nut 22-35 22-36 | 16.0-25.5 Front brake master cylinder mounting bolt 8-12 0.8—-1.2 60-85 Front brake caliper mounting bolt 20-30 2.0—3.0 [| 14.5-21.5 Front brake caliper pad mounting bolt 15-20 15—2.0 | 11.0-14.5 Brake hose union bolt (Front & Rear) 15-20 1.5—2.0 | _11.0-14.5 ‘Air bleeder valve (Front & Reer) 6-9 0.6-0.9 45-65 Brake disc bolt (Front & Rear) 18-28 18-28 13,0-20.0_| Front footrest bracket mounting bolt 18-28 7.82.8 | 13.0—20.0 Front footrest nut 42-66 42-66 | 30.5-47.5 Swingarm pivot nut 85—115 86—11.5 | 61.5—83.0 one mounting nut aa 60 ee ees Rear cushion lever/rod mounting nut 70-100 | 7.0100 | 60.5—72.5 Rear brake caliper mounting bolt 20-30 20-3.0 | 14.5-21.5 Rear brake caliper housing bot 30-36 3.0-3.6 | 21,5—26.0 Rear brake master cylinder mounting bolt 18-28 1.8-2.8 | _13.0—20.0 Rear brake master cylinder rod lock nut 15=20 16-20 | 110-148 Rear axle nut 85-115 86-115 | 61.5—83.0 Rear sprocket nut 48-72 35.0—52.0MAY-25-2082 @3:@7P FROM: TO: 18478730197 31_ SERVICING INFORMA TIGHTENING TORQUE CHART For other bolts and nuts listed previously, refer to this chart: an Diameter] Conventional or “a marked bolt 77 marked bolt @imm) Nem kgm Ibe Nem kgm ibe 4 70-20 | 01-02 75-30 | 0.16-0.3 | 10-20 5 2.0=4.0_ | 02-04 3.06.0 | 0.30.6 | 20-45 6 4.0-7.0 | 0.40.7 0 | 80-120 | 081.2 | 60-85 a [0.07160] 10-16 | 7.0-11.6 | 18.0-28.0 | 18-28 | 130-200 10 22,0—38.0 2.2-3.5 16.0—25.5 | 40,0-60.0 4.0-6.0 29.0—43,.5, 127] 38.0-65.0 | 85-6.5 | 26.5-40.0 | 70.0-100.0| 7.0-10.0 | 60.5—72.5 14 50.0—80.0 36.0-58.0 |110.0—160.0) 11.0--16.0 | 79.5—115.5) 16 80.0—130.0| '68.0—94,0 |170.0-~250.0| 17.0—25.0 |123.0~ 181.0) 78 _|130.0-190.0| 13.0-19.0 | 94.0—137.5]200. [0 a® Com * merked bolt 17" marked bolt =200.0| 20.0-28.0 |144,5—202.5) Conventional boltSERVICE DATA TO: 18478730197 Pit SERVICING INFORMATION VALVE + GUIDE mm (in) TEM ‘STANDARD Mir Vaive diam. i 258, 22.5 EX. (0-83) 04 and 33 ee others (0.33) " 6.6 ee (0.26) E04 and 72 = others (0.31) : 61 oie (0.24) Tappet clearance (when cold) | yy, one 0,200.30, aes (0,008—0.010) Valve guide to valve stem WN. =o clearance 0008 =9.001 EX. (0.0012--0.0022) aaa i 0.35 Valve stem deflection eee eae Valve guide LD. ieee Valve stem 0.0. an: 4.485—4.470 Pe (0.1784—0.1760) 0.05 Valve stem runout rere easy Valve head thickness TE oe cen Valve seat width eee Valve head radial runout ee OS Wag ne Wee evar 8, IN, & EX, vas Spring tension 7e.6-21.4 KG (1,047.2 Ibs) — eae at length 38 mm (1.5 in)MAY-25-2082 @3:@9P FROM: SERVICING INFORMATION CAMSHAFT + CYLINDER HEAD TO: 18478730197 Pe Unit: mm find Compression pressure 7 000—1 500 kPa TEM ‘STANDARD Tana. ‘Gam height E04 | 36312-36368 36.02 (1,4296—1.4318) (4.418) 34,542—34.598 34.25 tee £93 | (1.9599-1.3621) (1.348) cog | 30,312— 36,368 "36,02 (1.4298— 1.4318) (4.448) coa | 38,902-35,958 35.61 (1,4135—1.4157) (1.402) 34.122—34.178 33.83 ee £33 | (1,3433—1.3456) (1.332) E03 | 38.902—35,058 38.61 (4.4135—1.4187), (3.402) Camshaft journal oll clearance ly g Ex. 0.032—0.066 0.150 Eee {0.0013—0.0026) (0.0059) Camshaft journal holder 1.D. 22.012—22.025 WE (0.8666 —0.8671) Camshaft journal 0.D, 21,959—21.980 Mattia (0,8645—0.8654) Camshaft runout 0.10 IN. & EX — Poon Cam chain pin (at arrow “3 73th pin — Cylinder head distortion 0.20 (0.008) CYLINDER + PISTON + PISTON RING Unit: mm fin) THEM STANDARD MIT ‘B00 kPa (10-15 kalem?) (8 kavem®y 142~213 psi 1iapsi Compression pressure 200 kPa difference — zgiem’) 28 psi Piston to cylinder clearance 0.040-0.060 0.120 {0.0016 0.0024) (0.0047) Cylinder bore 5.000—65.015 65.090 (2.8591 —2.5596) (2.5626) Piston diam. 64.945 —64.970 (2.8569 —2.5579) ioces jure at_15 mm (0.6 in) from the skirt end, 5543) Cylinder distortion ow .608) Piston ving free end gap rar Appr (By on 8.0 6.4 eo eae APPIOX. (0.31) (0.25) Piston ring end gap 0.25-0.40 05 te et (0.010—0.016) (0.02) 0.25-0.40 0.5 2nd (0.010—0.016) (0.02)TO: 18478730197 P:3 SERVICING INFORMATION ee —rnrrnrn—r——o—ree TEM i ‘STANDARD LIMIT Piston fing to groove clearance aaa 0.18 sata Ist (0.007) 0.18 bac (0.007) Piston ring aroove width 0.83—0.85. ee Ist (0.032—0.033) 0,820.84. ae (0.632—0.033) ; 151-153 ol (0.059—0.060) Piston fing thickness a 0.77-0.79 (0.030—0.031) 0.77-0.78 Sata {0.030—0.031) Piston pin bore 76.002 — 16.008 16.030 (0.6210—0.6302) (0.6311) Fiston pin 0.0. 75,596— 16.000 15.980 (0.6298-0.6299) 40.6291) CONROD + CRANKSHAFT iTEM ‘STANDARD. Conrod small end 1.D. 76.010— 16.078 (0.6303—0.6306) Conrod big end side clearance 0.10—0.20 (0.604—0.008) Conrod big end width 20.95-21.00 (0.825-0.827) Crank pin width 21.10—21.15 (0.831—0.833) Conrod big end oil clearance 0.032—0.056 0.080 (0.0013—0.0022) {0,0031) Crank pin 0.0. "33.976— 34.000 (1,3376—1.3386) Crankshaft journal oll clearance! 0.020—0.044 0,080 (0.6008-0.0017) (0.0031) Crankshaft journal 0.0. 33.976 34.000 (1.3376—1.3386) Crankshaft thrust clearance 0.055—0.110 (0.6022—0.0043) Crankshaft thrust bearing _ 3,425—2.450 thickness, Right side (0.0955—0.0965) e 2.350—2.500 Lon eae (0/6825—0.0984) Crankshaft runout 0.08 40.002) OL PUMP TTEM ‘STANDARD Mi Oil pump reduction ratio 7.888 (75/43 x 37/34) — Oil pressure (at 60°C, 140°F) | Above 300 kPa (3.0 kg/em?, 43 psil Below 600 kPa (6.0 kg/em2, 85 psi) — at 3 000 r/min. ~TO: 18478730197 Pq CLUTCH Unit: mm fin) TEM ‘STANDARD. TMir Clutch lever play 10-15. (0.40.6) Drive plate thickness 2122.28 782 (0:083—0.090) (0.072) Driven plate distortion 0.10 (0.004) ‘Gluten spring free length 47.5 41.87) THERMOSTAT + RADIATOR + FAN TEM, ‘STANDARD. LNT Thermostat valve opening 74.5—78.5°C temperature (166.1—173.3°F) Thermostat vaive lift Over 7 mm (0.28 in) at 90°C (194°F) San Radiator cap valve openin i Lesnal ‘a 110 kPa (1.1 kg/em?, 15.6 psi) Cooling fan thermo- 2 ° eases Switetoperating ON Approx. 105°C (221°F) coerced OFF A 100°C (212°F) prox. 100° | ae Engi lant 50°C ingine coolant temperature y gauge resistance (122°) Deer eae. 80°C es Approx. 51.9 9 — 100°C ean es Approx. 27.4 @ 120°C (24°F) Approx. 16.12 — TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM. STANDARD cir Primary reduction ratio 7.744 (75/43), — Final reduction ratio, 3.071 (43/14) —= Gear ratios Tow. 3.142 (44/14) — 2nd) 2.058 (35/17) = 3rd 7.650 (33/20) — 4th 1.428 (30/21) ae ‘Sth 1.260 (29/23) = Top 7.120 (28/25) = ‘Shift fork to groove clearance 0.10—0.30 0.50 (0.004—0.012) (0.020) ‘Shift fork groove width 5,005.10 (0.197—0.201) Shift fork thickness 4.80—4.90. (0.189—0.193)MAY-25-2082 @3:@9P FROM: TO: 18478730197 SERVICING TEM ‘STANDARD hd Drive chain “Typa_[_RKSOGSVZ1 or DIDEOVAT — Links 108 links, ENDLESS a 20-pitch length — aber Brive chain slack 30-40 (1.2-7.6) aaa Gearshift lever height 35 (2.2) CARBURETOR SPECIFICATION ITEM £03, USA. £33, USA, (Calf, mode) Carburetor type. MIKUN! BOST36SS MIKUNI BDSTS3SS Bore size 36 mm 33 mm, 1D. No. 21E4 2IES Idle r/min. 7300: 100 r/min 73802 100 Fimin Float h EGE 1.0 mm (0,270.04 in) = Main jet m1 #1125 #1075 Main air jot WAS) 0.6 mm = Jet needle NY E97 395 Needle jet Ws.) a-9 0-8 Throttle valve hv) #120 = Pilot jet Ps.) #15 #10 Starter jet 16.8.) #475 = Pilot screw ) PRE-SET = Throttle cable play (0.5=1,0 mm (0.02—0.04 in) ELECTRICAL Unit: mm {in} TEM ‘SPCIFICATION. NOTE Tgnition timing FB.TD.C. below 1 500 tm £03 4°B.7.0.C. below 1 600 r/min. E33 Firing order 1:2-43 i Seon ie a 07-08 (0,028—0.032) ‘Spark performance. ‘Over 8 (0.3) at 1 atm. Signal coil resistance {Black— Green) ‘Tester range: Approx. 135—200 2 (x 100 Q) Ignition coil resistance i @ tap— O tap Tester range: Late Approx. 2.4—3.2 & x10) Plug cap—Plug cap ‘Tester range: Secondary| Approx. 30~40 ko tet kayMAY-25-2082 @3:10P FROM: 8.37_ SERVICING INEORMATION TO: 18478730197 P:6 TEM SPCIFIGATION NOTE Generator Sip rng 0.0. | Limits 14.0 10.55) a Brush length Limitz 4.5 (0.18) Generator Max, output = i The rotation of ‘Approx. 405 W at 6 000 r/min Le Regulated vokage ‘Above 13.5 V at 5 000 r/min. eee nee Fommntatt Limit: 0.2 (0.008) ND Starter relay resistance! 3250 Battery | Type designation YTX9-BS Capacity 12 V 28.6 kC (6 ARO HA ucaenae a! 1,320 at 20°C (68°F) Fuse size ‘ght LE TSA Headlight FAL 138 Turn signal 15 A Tgpition TOA TTailight 10-8 Main 30-A WATTAGE OT PECTFICATION a £03.33 The others Headlight HI 60 = Lo’ 55 = Position light a Taillight 5 = Brake light 2x2 = Turn signal 21 = Tachometer light Tx = Speedometer light V7x2 = Turn signal indicator Nght 34 js High beam indicator light 34 = Neutral indicator light Ex} = Gil pressure indicator Tight 3.4 = Fuel level indicator light 3.4 = License fight 5 = Engine coolant temp. meter 7 = light : BRAKE + WHEEL Unit: mm (in) TEM ‘STANDARD UNIT Rear brake pedal height 55 (2.2) Brake dise thickness 45202 a0 Eon (0.177 = 0.008) (0.48) 5.0 20.2 45 Lal (0.187 * 0.008) (0.18) Brake disc runout 0.30 (Front & Rear) = 40.612)MAY-25-2082 @3:10P FROM: TO: 18478730197 Pi? TEM ‘STANDARD TMT Waster cylinder bore aaa GeO FE TS 12.700— 12,743 a (0.8000—0.5017) Master cylinder piston diam. | gong (ees 52884, ; 12.657—12,684 ae (0,4983--0.4993) Ghindorbere—|_beeding 6000 1.60201 a a Liste "25.400— 25.450 railing (1,0000— 1.6020) 38. 180- 38.256 fear (1,5031—-1.5061) _ SSR [nae ae, 25.335—25.368 Trailing (0.9974—0.9987) 38.098 38,148 oon (1.5000— 1.5019) ‘Wheel rim runout : 20ne (Front & Rear) ae (0.08) Radiat — won ‘Wheel axle runout Front — iociel 0.25 cae (0.010) Tire size Front 720770 ZA17 — Rear 160/60 2R17 = Tire Wead depth Front — iooel 2.0 a (0.08) SUSPENSION Unit: mm (in) fE TEM ‘STANDARD [Umi NOTE Front fork stroke 120 GD Front fork spring free length 9, Front fork oll level 92, 3.6) Rear wheel wavel 7130 1) Swingarm pivot shaft runout eaTO: 18478730197 PB TIRE PRESSURE COLD INFLATION |__ SOLO RIDING DUAL RIDING TIRE PRESSURE [kPa [kg/cm] psi_| kPa [kg/cm] _psi FRONT 225 | 2.25 [33 | 250 | 2.50] 36 REAR 250 [2.50] 36 | 290 | 2.90 | 42 FUEL + OIL + ENGINE COOLANT TEM, ‘SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 67 pump octane ( "=!" method) 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 cosol- Vents and corrosion inhibitor is permi Fuel tank including reserve T7.OL (4.5/3.7 US/imp gal) Eee T6.0L {4.2/3.5 USiimp gal) coe reserve 4.0L (1.1/0.9 USiimp gall type. ‘SAE 10W/40, API SE or SF 7 capacity 3.000 mi Change (3.2/2.6 US/imp at 3300 mi Filter change | (3.5/2.9 US/Imp at 3 900 mi cota (4.1/3.4 US/Imp at) Front fork oll type Frok oil #10 Front fork oll capacity ‘503 mi {each leg) (17.0/17.7 US/imp oz) Brake fluid type DOT 4 Engine coolant type Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50:50. Engine coolant including 2 450 mi reserve (2.6/2.2 US/Imp qty E-03; U.S.A:, E-33: California U.S.A.)MAY-25-2082 @3:12P FROM: TO: 18478730197 Pit EMISSION CONTROL INFORMATION CONTENTS: EMISSION CONTROL CARBURETOR COMPONENTS EVAPORATIVE EMISSION CONTROL SYSTEM ~ CANISTER HOSE ROUTING PAIR SYSTEM DIAGRAM PAIR SYSTEM HOSE ROUTING --MAY-25-2002 @3:12P FROM: TO: 18478730197 Pie 84 EMISSION Ct ROL INFORMATION EMISSION CONTROL CARBURETOR COMPONENTS : RFGOOR motorcycles are equipped with precision, manufactured carburetors for emission level control. C These carburetors require special mixture control components and other precision adjustments to function properly. There are several carburetor mixture control components in each carburetor assembly. Three (3) of those components are machined te rwuoh closer toleranoea than standard machined oscburerorleta, These three (3) particular jets—MAIN JET, NEEDLE JET, PILOT JET—must not be replaced by stan- dard jets. To aid in identifying these three (3) jets a different design of letter and number are used. If replacement of these close tolerance jets becomes necessary. be sure to replace them with the same type close tolerance jets marked as in the examples shown below. c The jet needie is also of special manufacture, Only one clip position is provided on the jet needle. If replacement becomes necessary the jet needle may only be replaced with an equivalent perform- ing replacement component. Suzuki recommends that Genuine Suzuki Parts be utilized whenever possible for the best possible performance and durability. Conventional Figures Used on Standard Tolerance Jet |] D 3 4 5 6 7 8 9 @) Components Emission Type Figures Used on Close Toran fg ee Gh ¢ The carburetor specifications for the emission-controlled RFGOOR are as follows. Carburetor Main Needle Jet Pilot Pilot LD. No. Jet vet Needle Jet Screw ene ony |FFIO7S| 0-8 SEOs +10 PRE-SET DO NOT ADJUST ane #25) O-F SE97 FHS The pilot screw is pre-set by the factory utilizing specialized testing and adjusting procedures. The G pilot screw is not adjustable as the idle circuit is “'sealed’” after factory adjustment. Adjusting, inter- ferring with, improper replacement, or resetting of any of the carburetor components may adversely affect carburetor performance and cause the motorcycle to exceed the exhaust emission level limits. If persons, who are unaware of these special carburetor servicing requirements tamper with the car- buretors the Suzuki dealer should restore the carburetors to their original condition or if unable to ( effect repairs, contact the distributors representative for further technical information and assistance,MAY-25-2002 @3:12P FROM: TO: 18478730197 Ps EMISSION CONTROL INFORMATION 9.2 EVAPORATIVE EMISSION CONTROL SYSTEM (Only for California model) Fuel filler cap Fuol-vapor separator Fuel filler pipe Fue! hose Purge control valve ~<—— HC vaPoR oe FEL wt---- FRESH AIRMAY-25-2002 @3:12P FROM: TO: 18478730197 9.3 EMISSION CONTROL INFORMATION CANISTER HOSE ROUTING (Only for California model) Fuel-vepor separator Purge hose No.2 Purge hose No.1 Surge hose Purge hose No.1 Pi4 Wel Purge hose No.2MAY-25-2002 @3:13P FROM: TO: 18478730197 PS EMISSION CONTROL INFORMATION 9.8 PAIR (AIR SUPPLY) SYSTEM DIAGRAM (Only for California model) PAIR control vatveMAY-25-2082 @3:13P FROM: TO: 18478730197 P:6 9.6 EMISSION CONTROL INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING (Only for California model) PAIR control valve No.1 hose PAIR control valve vacuum hose PAIR air cleaner hose PAIR control valve No.2 hose PAIR control ve ain rood van’ road van No.2 hose Sy PAIR reed valve No.1 hose PAIR reed valve pipe No.2 PAIR ait pipe PAIR air pipe No.2 - No.1MAY-25-2082 @3:15P FROM: TO: 18478730197 Pit rm UG ee eee 1621) This chapter describes service data, service specifications and servicing procedures which differ from those of the RF6OORR (’94-model). NOTE: * Any differences between RFGOORR (‘94-model) and RFGOORS ('95-model) in specifications and service date are cleary indicated with the asterisk marks (*) * Please refer to the chapters 1 through 9 for details which are not given in this chapter. CONTENTS: SPECIFICATIONS erosecseenuen 10-7 SERVICE DATA - 10. 3 SERVICE INFORMATION 10-12 STARTER CLUTCH « 10-12 EXHAUST PIPE/MUFFLER MOUNTING -- + 10-15 OIL PAN AND OIL SUMP FILTER --- + 10-15 + 10-16 + 10-16 CARBURETOR REAR BRAKE CALIPER -------MAY-25-2082 @3:16P FROM: TO: 18478730197 Pe 10-1, RFGOORS ('95,MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length 2.110 mm (83.1 in) ..... For E-02,03,04,24,25, 28,33,34,53 2.160 mm (85.0 in) ..... For E-18,22 Overall width 710 mm (28.0 in) ‘Overall height 1.175 mm (46.3 in) Wheelbase .. 1430 mm (56.3 in) ..... For E-03,18,33 435 mm (56.5 in) .. 120 mm ( 4.7 in) . For the others Ground clearance Dry mass . 195 kg (429 Ibs) 198 kg (436 Ibs) ..... E-33 only ENGINE Type .. Four-stroke, Water-cooled, DOHC, TSCC. ea 65.0 mm (2.859 in) 45.2 mm (1.780 in) Number of cylinders Bore Stroke Piston displacement 599 em (36.6 cu. in} Carburetor MIKUNI BDST33 ..... For E-18,33 MIKUN! BDSTS6 ..... For the others Air cleaner Non-woven fabric element Starter system . Electric starter Lubrication system . Wet sump TRANSMISSION Clutch Transmission .. Gearshift pattern... Primary reduction ratio Final reduction ratio s+ Wet multi-plate type 6-speed constant mesh 1-down, 5-up 1,744 (75/43) 3.071 (43/14) ..... For -03,18,33 *3,000 (42/14) ..... For the others Gear ratios, Low... seveeeee 3.142 (44/74) 2nd .. 2.058 (35/17) 3rd 1.660 (33/20) 4th 1.428 (30/21) 5th 1.260 (29/23) 1,120 (28/25) seuss *TAKASAGO RKSOMFOZ1, 108 links chain.MAY-25-2082 @3:16P FROM: TO: 18478730197 P:3 RFGUORS ('95-MODEL) 10-2 CHASSIS Front suspension ... Telescopic, coil spring, oil damped, spring pre-load adjustable. Link type system, cil damped, coil spring, spring pre-load adjustable and rebound damping force ad- Rear suspension . justable. Steering angle . esssceesense 30° (right & left) Caster 65° Trail . ‘Turning radius .. Front brake Rear brake Front tire size .. Rear tire size .. Front fork stroke 103 mm (4.1 in) 3.2 m (10.5 ft) Disc brake, twin Disc brake 120/70 ZR17, tubeless 160/60 ZR17, tubeless 120 mm (4.7 in) Rear wheel travel .. 130 mm (5.1 in) ELECTRICAL Ignition type Electronic ignition (Fully Transistorized} 4° B.T.D.C. at 1500 r/min ..... For E-33 *7° B.T.D,C. at 1500 r/min ..... For the others: N.G.K.: CR9E, NIPPONDENSO U27ESR-N 12V 28.8 kC (8 Ani/10 HR Ignition timing Spark plug Battery -. Generator ‘Three-phase A.C. Generator Main fuse 308 Fuse : 15/18/15/10/10A Headlight « . 12V 60/5BW ‘Turn signal light 12V 21W x4 Parking or city light . 12V 4W ..... Except for £-03,24,28,33 Taillight . 12V 5W Brake fight . 12V 21W x2 License plate light... . 12V 5W Speedometer light 2 12V1.7W x2 Tachometer light . 12V 1,.7Wx2 Engine coolant temp. meter light sieves 12V 1.7W Neutral indicator light . 12V 3.4W High beam indicator . 12 3.4W Turn signal indicator light 12V 3.4W Oil pressure indicator light ve 12 3.4W Fuel level indicator light 12V 3.4W CAPACITIES Fuel tank, including reserve 16.0 L (4.2/3.5 US/Imp gal) ..... For E-33 . For the others 17.0 L (4.8/3.7 US/imp gal) .. 3.000 mi (3.2/2.6 US/Imp at} 3 300 mi (3.5/2.9 US/Imp at) 3 900 mi (4.1/3.4 US/Imp at) 803 mi (17.0/17.7 US/Imp 02) 2 460 mi (2.6/2.2 US/imp at) Engine oil, oil change .... with filter change overhaul Front fork oil. Coolant .. These specifications are subject to change without notice.MAY-25-2082 @3:16P FROM: TO: 18478730197 Pq 103 AFGOORS ('95:MODEL) SERVICE DATA VALVE + GUIDE Unit: mm (in) TEM ‘STANDARD Mit Valve diam. i 235, ae 22.6 z a (0.89) ive W 04 and a3 =n eee as others (0.3) : 6.6 ile: (0.26) £04 and 79 : others (0.31) : 6.1 fue (0.24) ‘Tappet clearance (when cold) | yy, ae ae 0.20—0.30 a (0.08—0.010) Ive guide to valve stem 0.020—0.047 Gemeente me (0.6008—0.0019) a 0.030—0.057 ane a (0.0012—0.0022) i 0.38 Vaive stem deflection are ata eae mon] eet | — Reece IN. (ori7s8—0.1764) aan 4455-4470 fe (0.1754—0.1760) Valve stem ranout woe oo Valve head thickness eee oon Valve seat width Wen ose adden Valve head radial runout nee oes Valve spring free length 43.0 UW & BX (1.69) a HEDIS, = es at length 38 mm (1.5 in)TO: 18478730197 PS RFBOORS (95-MODEL) 10-4 CAMSHAFT + CYLINDER HEAD Unit: men Gin) TEM STANDARD, omar Cam height cos | 36,312 —36,368 36,02 7 (1.4296—1.4318) | _(1.418) 34.642 34.508 34,25 IN. | E18,33 | (1.3599—1.3621) |__11.348) "36.312 36.368 36.02 Others | (1.4296—1.4318) |_(1.418) E04 | 39,002—35,988 35.61 : (.4136—1.4187) | _(3.402) 34122-34178 33,83 x, | £18.33 | (1,3433—1.3450) | __ (1.332) 35,902—35.958 35.61 Others | (7.4135—1.157) | _(1.402) Camshaft journal oll clearance ly @ EX 0,032—0.066 0.150 ik {0.6013—0.0026) (0.0069) Camshaft journal holder LD. 22.012—22,025 eee (0.8666—0.8671) 21,959—21.980 __ Camshaft journal 0.D. (0.8645—0.8654) Camshaft runout 0.10 (0.004) ‘Cam chain pin (at arrow 73th pin — Cylinder head distortion 0,20 (0.008) CYLINDER + PISTON + PISTON RING Unit: mm fin) TEM STANDARD, LIMIT. Compression pressure 7 000-1 500 kPa ‘B00 kPa (105518, kalemt) (8 kelem*) 142—213 psi 14psi ‘Compression pressure 200 kPa difference —_— (2igiem*) 28 psi Piston to cylinder clearance 0.040—0.060 0,120 {0.0016—0.0024) (0.0047) Cylinder bore 65,000—65.015 65.090 (2.8591 — 2.5596) (2.5626) Piston diam. 64,945—64.970 = 64,880 (2.8569—2.5579) ose) [Measure at_15 mm (0.6 in) from the skit end Cylinder distortion 0.20, (0.008) Piston ring free end gap ar aaorex. «Cy 2 8.0 6.4 ans APPFOX. (0.31) (0.28) Piston ring end gap 0.25—0.40 0.6 iho (0.010—0.016) 19.02) og 0.25—0.40 05 (0.010—0.016) (0.02)(0.002) TO: 18478730197 0-5 RFBOORS (95-MODEL TEM ‘STANDARD. TMT ston ring to groove sees 0.18 Clearance = (0.007) 0.18 oo (0.0071 Piston fing groove width 083—0.85, 7 is (0.032—0.033) 0.82—0.84 laa (0.032—0.033) a 1,811.53 z {0,059—0.060) Piston Fing thickness ae 0.77—0.79 : (0.030—0.031) 0.77—0.79 aac bisa (0,630—0.031) Piston pin bore 76.002 16.008 76.030 (0.6210—0.6302) (0.6311) Piston pin 0.0. 16.986— 16.000 15.980 (0.6298 0.6299) (0.6291) CONROD + CRANKSHAFT Unit: mm (in) TEM ‘STANDARD. Conred small end 1-0. 16,010— 16.018 (0.6303~0.6306) Conrod big end side clearance 0.10—0.20 (0.604—0.008) Conrod big end width 20.95—21.00 (0.825—0.827) Crank pin width 21.10—21.15 (0.831—0.833) Conrod big end oil clearance 0.032—0.056 0.080 {0.6013—0.0022) (0.0031) Crank pin 0.0. 33.976—34,000 (1.3376—1.3386) Crankshaft journal of 0,020—0.044 0,080 clearance (0.0008—-0.0017) (0.0031) Crankshaft journal 0.. 33.976— 34.000 (1,3376— 1.3386) Crankshaft thrust clearance 0.055—0.110 (0.0022—0.0043) Crankshaft thrust bearing 5 2,425~ 2.450 thickness. Right side 40.0955—0.0965) 5 2.350—2.500 ena Eernsee. (0.6825—0.0984) Crankshaft runout 0,05MAY-25-2002 83: o 17P FROM: TO: 18478730197 Pi? RFGDORS (95-MODEL) 10-6 OlL PUMP. TEM STANDARD, uiMiT Oil pump reduction ratio 1.898 (75/43 x 37/34) a Di pressure (at 60°C, 140°F}| Above 300 KPa (3.0 ka/cmé, 43 psi) Below 600 kPa (6.0 ka/cm?, 85 psi) — ‘at_3 000 r/min, CLUTCH ‘Unit: mm (in) rem ‘STANDARD LIMIT Clutch lever play 10-15 (0.4—0.6) Drive plate thickness 2.12—2.28 7.82 (0.083—0.090) (0.072) Driven plate distortion 0.10 (0.004) Clutch spring free length 47.5 (1.87) THERMOSTAT + RADIATOR + FAN 1TEM. ‘STANDARD LIMIT | Thermostat valve opening 74,6—78,5°C temperature (186.1—173.3°F) Thermostat valve lift Over 7 mm (0.28 in) at 90°C (194°F) = Radiator cap valve opening 5 = pressure 110 kPa (1.1 kg/em?, 15.6 psi) Cooling fan thermo- 2 2 ae Snitct operating on Approx. 105°C (221°F) temperature OFF ‘Approx. 100°C (212°F) — Engine coolant temperature 50°C a gauge resistance (122°) eopo See : BOeC cua eer ‘Approx. 51.9 @ TOO" ae 8308) Approx. 27.4 @ 120°C aaa (248°F) Approx. 16.1 2 TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio TEM ‘STANDARD TIMI Primary reduction ratio 7.744 (75/43) = Final reduction ratio £-03,18,33] 3.071 (43/14) oe [The others 73.000 (42/14) — Gear ratios Low EREVACC AE — 2nd 2,058 (36/17) = 3rd 1.650 (33/20) — ‘ath 7.428 (30/21) — Sth 1.260 (29/23) — Tow 1,120 (28/25) —MAY-25-2082 @3:17P FROM: TO: 18478730197 PB 107 araonns cosmopey Trem ‘STANDARD, TMT Shift Tork to groove clearance 0.40—0.30, 0.50 (0.604—0.012) .020 Shift fork groove width 5.00—5.10 (0.197=0.201) Shift fork thickness 4.80—4.50 (0.189-~0.193) Drive chain Type RKSOMFOZ1 = Links 708 links, ENDLESS —— 20-pitch length — aoe Drive chain slack 30-40 sana (1.2=1.8) Gearshift lever height 70, (2.8) *CARBURETOR 03, U.S.A. | (Calif. model) Carburetor type. IMIKUNT BDSTS6SS|MIKUNI BOST33SS = Bore size 36 mm 33 mm = 7D. No. 21EG 26H SEN. Tale /min. 1300 100 rimin | 1 3602 100 rimin | 1 200% 100 r/min, Float height 6.9 1,0 mm (0.27 0.04 in) Main jet iwi wes #1075 Fie Main air jet M.A.) Fins. 0.8 mm, 0.7 mm 0.6 mm eects am Jet needle oO) 3Eo7 5E9 5D44-3rd Noodle jet (NJ.) a-9 o-8 0-9 Throttle valve Tv.) #120 = #125 Pilot jet J.) | ‘#15 #10 #125 ‘Starter jet 16.5.) 447.6 = =< Pilot screw 5.) es PRE-SET need (1-%2 turns out) “Throvtle cable play “CARBURETOR SPECIFICATION rem £02 and ocan £-22,24 £18 | E-22-Utype Carbureter type MIKUNT = MIKUNT MIKUNI BDST36SS eosTs3ss_| sDsT36ss Bore size 35 mm = 33 mm 36 mm LD. No. DEF 216s 2iEL ZiEK Tale r/min. 13002 100 = = tiimin Float height ©9210 mm (0.27 20.04 in)TO: 18478730197 Pit RFGOORS (‘95-MODEL) 10.8 a oe 10.8 ‘SPECIFICATION ITEM £02 and pies 22,24 £18 E-22-Utype WJj} #1125 = #110 #120 Main air ji -A.J.1 | #184: 0.6 mm] ain air jet (MAW [arias 0.6 mm, = oeu aie Jet needle GND] SD44-3ra = BEgs-4th | 6D44-2nd Needle jet WJ] 0-9 = 0-8 = Throttle valve (hv) ]__# 125 = #120 #125 Pilot jet (Pld) 12.6 = #10 #25 Starter jet (GS). #47.5 = = = Pilot screw {P.S.)| PRESET = = PRE-SET 1-¥e turns out} (4 turn out) ‘Throttie cable play O5—1.0 mm (0.02—0.04 in) ELECTRICAL ITEM ‘SPGIFICATION Ignition timing 4° B.T.D.C. below 1 500 r/min. 77 BDC. Firing order Spark plug NGK; CASE . Type ND: U27ESR-N 0.7-0.8 Gap (0.028-0.032) ‘Spark performance ‘Over 810.3) at 7 atm. Signal coil resistance (Black—Green) Tester range: Approx. 136-200 @ 16100 Ignition coil resistance : Ow Ow Tester range: pamery. Approx. 2.4—3.2 @ (x19) Plug cap—Plug cap Tester range: Secondary Approx. 30—40 kf (x 1 ka) Generator ‘Siping 0.0. 74.0 (0.55) ne Brush length Limit: 4.5 (0.18) Generator Max, output i The rotation oF Approx. 405 W at 6 000 r/min ee Regulated voltage ‘Above 13.5 V at 6 000 r/min. Starter motor Tommutator ; unary Limit: 0.2 (0.008) ND Starter relay resistance 3-50 Battery [Type designation YTx9-BS Capacity 12 V 28.8 KC (8 Ah)10 HR Standard aeiaee electrolyte 8.G. deed eu aera keeia Fuse size HI TSA Headlight [HE we Turn signal 15 A Ignition 10a Taillight 10. Main 30ATO: 18478730197 Pre 10.8 RFGOORS (95.-MODEL) WATTAGE Unit: W ‘SPECIFICATION bide £03.24, 28,53 The others Headlight HI 60 = 10 55 = Position light 4 alight 5 = Brake light 2ix2 = Turn signal light 2ix4 = Tachometer light Tad = Speedometer light 17x = “Turn signal indicator ight 34 = High beam indicator light 34 = Neutral indicator light 3.4 : = Oil pressure indicator light 3.4 = Fuel level indicator light, 3.4 = License fight 5 = Engine coolant temp. meter ra = Lake : BRAKE + WHEEL Unit: mm (in) Trem ale ‘STANDARD. TuMiT Rear brake pedal height Brake disc thickness eon an rm 0.2 45 ee 0.008) (0.18) Brake disc ranout 0.30 (Front & Rear) (0.012) Master cylinder bore oe Be IeH aes, 12.700— 12,743 Masel (0.6000-0.5017) Master cylinder piston diam. | prong eee 88s, 12,657— 12,084 a {0.4983—0.4993) Brake caliper as 25,400—25.450 cylinder bore - Front {4.0000—1.0020) Trailing a 6000—7.6020) ae B0— 38,256 dcal G'eoa— 1.8061) aaa | Leeda Benes, | : aa fom 25.335 25.368 Eeenee (0.9974—0.9987) 38,098—38.148 aaee eae (3,5000— 1.6019)TO: 18478730197 P:3 RFGOORS (95-MODEL) 10.10 TEM ‘STANDARD LMT Wheel rim runout ran 2.0 (Front & Rear} (0.08) i aaa 2.0. Radial (0.08) ‘Wheel exle runout 0.25 front (0.010) 0.26 fea (0.010) Tire size Front 120770 ZA17 — Rear 160/60 ZR17 = Tire wead depth 76 Front iaoe 2.0 neat (0.08) SUSPENSION Unit: mm fin) TEM. STANDARD, IMT NOTE Front fork stroke 120 (4.7) Front fork spring free length 390 (15.4) Front fork oil level 92 a (3.6) Rear wheel travel 130 (8.1) Swingarm pivot shaft runout 03 (0.01) FUEL + OIL+ ENGINE COOLANT TEM ‘SPECI NOTE Fuel type Use only unleaded gasoline of at least 85 pump octane ( © } or 91 octane or higher rated by the research methed. Gasoline containing MTBE (Methyl Tertiary | €-03,33 Butyl Ether), less than 10% ethanol, or less ‘than 5% methanol with appropriate cosol- vents and corrosion inhibitor is permissible. Use only unleaded gasoline of at least 87 pump octane | ©5"" method) or 91 octane £28 or higher rated by the Research Method. Gasoline used should be graded 85-95 oc- tane or higher. An unleaded gasoline is | The others recommended. Fuel tank including reserve 760. cs (4.2/3.5 US/Imp galb z T7.0L (4.5/3.7 US/imp gal) The others reserve FOL (1.1/0.9 US/imp gal)10-11, RFSOORS ('95-MODE! TO: 18478730197 TTEM. Engine oil type ‘SPECIFICATION NOTE 'SAE_10W/40. API SE or SF Engine oil capacity 3000 ml Change (3.2/2.6 US/imp av) 3 300 mi Filter change | (3.8/2.9 US/Imp qt) 3 900 mi vennay (4.1/3.4 US/imp at) Front fork oll type Frok oil #10 Front fork oil capacity 503 mi {each leg) (17.0/17.7 US/mp 02) Brake fluid type DOT 4 Engine coolant type Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50:50. jine coolant including ve 2 450 mi (2.6/2.2 US/imp at) TIRE PRESSURE [E-03,33 markets] COLD INFLATION [|__ SOLO RIDING DUAL RIDING TIRE PRESSURE [KPa Ikq/ema]_psi_| kPa_|ka/em®|_psi FRONT, 225 2.25 33 | 250 | 2.60 [36 REAR 250 2.50 | 36 | 290 | 2.80 [42 TIRE PRESSURE [The other markets] COLD INFLATION |__SOLO AIDING DUAL RIDING TIRE PRESSURE [kPa _|kg/em?|_ psi FRONT 250 | 2.50 | 36 REAR 250 | 2.50 | 36MAY-25-2082 @3:20P FROM: TO: 18478730197 PS REGOORS ('35-MODEL) 10-12 SERVICE INFORMATION STARTER CLUTCH Storer chtch pighteing torave: YOu og 60 Nem (5.0 kgm. 36.0 Ib-ft) 10 Neen (1.0 kon, 7.0 tt) Generator shat ‘Gonerator damper, Generator riven gear Staner clutch damper ‘Starter ivan gearMAY-25-2082 @3:20P FROM: TO: 18478730197 P:6 DISASSEMBLY AND INSPECTION * Hold the starter clutch shaft to use a vise and appropri- ate pieces of soft metals, and remove the nut as shown in the Fig. CAUTION: This is @ left-hand thread nut. ‘* Remove the generator driven gear assembly. ‘© Inspect the dampers for wear and damage. If any defects are found, replace the dampers as a set. '* Inspect the starter clutch and its contacting surface of the starter driven gear for wear or damage. If they are found to be damaged, replace them with new ones, ¢ Remove the starter clutch and its driven gear. ‘* Remove the driven gear from the starter clutch, ‘* Inspect the generator damper for damage If any defects are found, replace the damper or starter clutch shaft assembly.MAY-25-2082 @3:20P FROM: ‘+ Remove the bearing and generator damper from the starter clutch shaft with 2 bearing puller. NOTE: Before removing the bearing, rotate the outer race by hand to inspect for abnormal noise and smooth rotation. CAUTION: ‘The removed bearing should be replaced with a new one. ‘¢ Remove the bearing from the generator damper. REASSEMBLY Assemble the starter clutch in the reverse order of disas- sembly. Pay attention to the following points: NOTE: Apply engine oil to each starter clutch part before reas- sembling. * Install the bearing to the generator damper with a bear- ing installer. (Bd 09951-16080: Bearing installer ‘ Install the starter clutch shaft into the generator damper by tapping with a plastic mallet. TO: 18478730197 Pi? AFGOORS ['95-MODEL) 10-14MAY-25-2082 @3:21P FROM: TO: 18478730197 PB 10-15_RFBOORS (‘95-MODEL) EXHAUST PIPE/MUFFLER MOUNTING TIGHTENING TORQUE Nem | kg-m_ | tb-tt (oem eet [2s [es OIL PAN AND OIL SUMP FILTER OL PAN ‘OIL SUMP FILTER ‘94-model '95-model *94.-model *96-modelMAY-25-2082 @3:21P FROM: TO: 18478730197 RFGOORS ( CARBURETOR PILOT SCREW REMOVAL AND INSTALLATION * Remove the plug by carefully punching a hole in it using an awl or suitable tool. * Before removing the pilot screw, determine the setting by slowly turing it clockwise and count the number of turns required to lightly seat the screw. Turn the screw counterclockwise to remove it. NOTE: This counted number is important when reassembling pilot screw to original position. + When installing the pilot screw, tum it in fully but not tight: ly. From that position turn it out the same number as counted during removal. * Install the new plug in the pilot screw hole. REAR BRAKE CALIPER caliper mounting bolt: 28—33 N-m (2.8—3.3 kg-m, 20.0—24.0 lb-ft)MAY-25-2082 @3:24P FROM: TO: 18478730197 RFGOORT (‘96-MODEL) This chapter describes service data and service information which differ from those of the RF6QORS (’95-model). ‘NOTE: * Any differences between RFGOORS (’95-model) and RF6OORT (’96-model) in service data are cleary indicated with the asterisk marks (*). © Please refer to the chapters 1 through 10 for details which are not given in this chapter. CONTENTS: SPECIFICATIONS - m7 SERVICE DATA --+s11es0ees000 11-2 SERVICE INFORMATION ~ 10-17 oes 1914 REAR BRAKE AND TORQUE LINK ROD11-1 AFBOORT ('95-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS. Sverall length Overall wider Sverait“helghe: Wineolbara Ground clearance Seat" heiot ENGINE Types Valve" eigsrance,” Wy. uber of evinces Bore Seok | : Piston cioplocernant erresed comgresion ra Gerouretor reteset. ‘Starer aysiem: Cubreanon ‘syster ‘Fronemiscion Goarsrit patie Beary reduction rate Seariaics, tow na Bed o> a sen Top Final reduction fatios sss issise bas Drive chai ‘CHASSIS Front suspension Rewr suspension Eromt suspension stroke Bear suspension Wawel. 2s. F as Foor tre ae: gurcTnicaL ‘Gnion timing: Spark plug Battery Generaror 222 Grouit breaker. Fuse. Heotigh Posi igh fn Sona Tatighe cee ke toh ise pat ot Speedometer itt Tethometer tight Neutra indicator tight. ign beam iatcetor light un aia htc Ha redoure indicator ight Pu indicator ight ‘caracrnies Foe! tank, inckiing reserve : Reser none ols With titer ‘change’ + cooine coattails s ine coolant Front tore ot 2 169 mm (96.0 in}... £18, 22 2170 mm (33.1 fa}. 2 Others 730 mn (28.0 int 138 mn (48.3 439 mm (96.3 | 120 mam (04-7 i 780 ann (94:4 tab 195 ky 1828 Wa)... Others 198 83 (238 took 2 <7. ESS Four-stroke, liauld-cooted, DOHC, TSCC 6:10""0.20 mm (0.004~0.008 fn} 9:20-8:38 rum 1.008—8.012 85.9 mm 12.85: 35.2 mun {1.780 in} 898 cm (36.6 cu. im) Sort BOSTSE, fe Non woven fabric element Stara’ mover Wer sump, Wer mult plate type Grapaed constant mesh Taw, ug. 503, 18, 99 ecOMFOD', 168 trie Tere, col con, amon, png lon tal TES Seo ane i ae wy goimm (4.7 ta) oa 18 193 mm (4.06 1m) 388 32 most Disk broke, twin, nya Disk brexe, hydaull Saov7ogai? yeoveozny esr onion sits) 4800 min BT. beow £1833 erBe Sthere NGI GROE of NIPPONDENSO U27ESRN Tivee:phase A.C generator 3 08 TS/isyrov1s/104 WV Bbosew 12V GW except £26,28 1By iw 13y bw Simp gal)... E83 Sim gel: Others Usiime a) PT Using 22)TO: 18478730197 P:3 AFGOORT (‘96-MODEL) 11.2 SERVICE DATA VALVE + GUIDE Unit: mm (in) TEM STANDARD. UNIT Valve nl 25.6 EX. a Valve Hitt 04 ond —_ others WN. E18 E04 and others, EX. E18 — Tappet clearance (when cold) | yy, 0.10—0.20 — =F 0,20—0-30 : (0.008—0.010) Valve guide to vaive stem 7 0,020—0.047 clearance : (0.0008—0.0019) x 0.030—0.057 ; (0.6012—0.0022) Valve stem deflection 05 ee 40.014) Valve guide 1.0. Z,800—4.512 WE SIEn (0.1772—-0.1778) Valve stem 0.0. ii 4,465—4.480 jae (9.1758—0.1764) 7 4,455—4.470 (0.1784—0.1760) Vaive stem runout 0.05 IN. & EX. a Valve head thickness 08 atlases (0.02) Valve seat width o9-11 Utes (0.035—0.043) Vaive head radial ronout 0.08 Neues (0.001) Valve spring free lenath 43.0 (IN. & EX.) (1.68) Valve spring tension 78.6-21.4 kg (IN. & EX) (41.0—47-2 Ibs) — at lengths 38 mm (1.5 in)MAY-25-2082 @3:24P FROM: 11-3 RFGOORT ( MODEL) TO: 18478730197 CAMSHAFT + CYLINDER HEAD Unit: mm tind TEM. ‘STANDARD. TiMir Cam height £04 | 36312-36368 36.02 (1,4296—1.4318) | _(1.418) 34,642—34.598 34.25 IN. £18.33 | (7,3599-1.3621) | __(1.548) 36.312—36.368 36,02 Others | (7.4206—1.4318) |_ (1.418) E04 | 35,902—35,958 35.61 (1-4135~1.4187) |__ (1.402) 34.122—34,178 33.83 EX, [618,33 | (1.3433—1.9466) | __ (1.332) 35.902—35.958 35.61 Others | (7.4135—1.4157) | __ (1.402) Camshaft journal oil clearance 0,032—0.066 0,150 pas {0.0013--0,0026) 40.0059) Camshaft journal holder LD 22.012 22.026 ee (0.8666—0.8671) Camshaft journal 0.0. 21.959—21.980 ee (0.8645—0.8654) Camshaft runout 0.10 IN, & EX (Coos) Cam chain pin (at arrow 3") Tath pin — Cylinder head distortion 0,20 (0.008) CYLINDER + PISTON + PISTON RING Unit: mm (in) TEM STANDARD Mit Compression pressure 7 500 kPa 00 kPa ( kglem) (8 afer?) 142~213 psi 4psi Compression pressure 200 kPa, difference — (2xglem*y 28 psi Piston to cylinder clearance 0.040-0.060 0.120 (0.6016—0.0024) (0.0047) Cylinder bore 65.000--66.015 65.080 (2.5591 — 2.5596) (2.5826) Piston dian. 64,945—64.970 (2.5569 2.5579) rrr jeasure at 15 mm (06 in) from the skit end| _ (2.5643) Cylinder distortion 0.20 (0.008) Piston ring free end gap 76 6.0 ° asthe ApPrOX. (0.28) (0.24) and | R Approx. (94) Piston ring end gap ag 08885) a 0.25—0.40 {0.010-0.016)TO: 18478730197 PS REGOURT (96-MODEL) 11.4 TEM ‘STANDARD umit Piston ring to groove clearance) 45, ae easy i 0.18 and (0.007) Piston ting groove width 0,830.85 ace oe ed (0.032—0.033) 0.82—0.84 one {0.032—0.033) aa 1.51—1.53 ds (0,089—0.060) Piston ring thickness 5 0.77-0.79 st {0.030—0.031) 0.77-0.79 a (0.030 -0.031) Piston pin bore 76,002— 16.008 76.030 (0.6210—0.6302) (0.631) Piston pin O.D. 15.996— 16.000 15.980 (0,6298—0.6299) (0.6291) CONROD + CRANKSHAFT Unit: mm (in) TEM STANDARD, Timi Tonrod small end 1D. 76.010— 16.018 76,040 (0.6303—0.6306) (0.6315) Tonrod big end side clearance 0.10—0.20 0.30 (0.004—0.008) (0.010) ‘Conrad big end width 20.95-21.00 (0.825— 0.8271 Crank pin width 21.10—21,15 (0.831 0.833) Conred big end oll clearance (0.032—0.056 6,080 {0.0013—0.0022) (0.0031) Crank pin 0.0, 33.976—34.000 (1.3376 —1.3386) Crankshaft journal off clearance| 0.020—0.044 0,080 {0,6008—0.0017) (0.0031) Crankshaft journal 0.D. 33.976—34.000 (1:33 76— 1.3386) Crankshaft thrust clearance 0.055—0.110, {0,6022--0.0043) Crankshaft thrust Beating ; 2.475—2.450 thickness Right side (0.6965—0.0968) 5 2,350—2.500 aca tenes {0.0925— 0.0984) Crankshaft runout 0.05 (0.002)MAY-25-2082 @3:25P FROM: TO: 18478730197 P:6 OIL PUMP c TTEM STANDARD. uM Gil pump reduction ratio 7,898 (75/43 x 37/34) — Gil pressure (at 60°C, 140°F)| Above 300 kPa (3.0 kg/om?, 43 psi jem? 86 psi) cone CLUTCH Unit mm (in) Tem MIT Chuteh lever play oe Drive plate thickness 2.12—2.28 7.82, (0.683-0.030) (0.072) Driven plate distortion 0.10 (0.004) Clutch spring free length 475 sid : 11.87) THERMOSTAT + RADIATOR + FAN TEM ‘STANDARD MrT Thermostat valve opening 74.5—78.5°C temperature (166.1—173.3°F) Thermostat vaive lift ‘Over 7 mm (0.28 in) at 90°C (194°F) Radiator cap valve opening 2, i) ee 110 kPa (1.1 kg/em?, 18.6 psi) Gooling fan thermo- 2 I See a atne ON Approx. 105°C (221°F) temperature OFF Approx. 100°C (212°F) Engine coolant temperature 50°C gauge resistance (122°) Approx. 153.9 2 80°C pir Approx. 51.9 2 100°C (292°F) Approx. 27.4.9 120°C aaneey Approx. 16.1 9 TRANSMISSION + DRIVE CHAIN Unit: mm EM. ‘STANDARD. Primary reduction ratio 1.744 (75/43) = Final reduction ratio 03,18 33 3.071 (43/14) —— [The others, 3.000 (42/14) a Gear ratios Low 3.142 (44/74) = 2nd 2.058 (35/17) = 3rd 1.650 (33/20) — [4th 1.428 (30/21) — Bth 1.260 (29/23) = Top 1.120 (28/25) =TO: 18478730197 RFBOORT (96-MODEL) 11.6 Pi? TEN ‘STANDARD. Mit Shift fork to groove clearance 0.10-9.30 0.50 (0.004—0.012) (0,020) Shift fork groove width 5.00—6.10 (0.187—0:201) Shift fork thickness 4,80—4.80, (0.189-0.193) Brive chain Type RKSOMFOZT = Links 7108 links, ENDLESS —= 20-pitch length — neal Drive chain slack 30-40 (1.2=1.6) Gearshift lever height 70 (2.8) CARBURETOR rm a Siseuaaen (Calif_ model) Carburetor type IMIKUNI BOSTS6SS|MIKUNI BDST33S5|MIKUNI BDSTS6SS| Bore size 36 mm 33 mm 36 mm 1.D. No. 2166 216H 2IEN {ale c/mi 7300: 100 r/min | 1 350 100 r/min | 1 200+ 100 r/min Float height 6.92 1,0 mm (0.27+0.04 in) Main jet Mi) ees #1095 ez ‘Main ir jet M.A) 184: 0.6 mm, om eae 2283:1.0 mm wet needle ND SES? E99 544-314 ‘Needle jet (NJ) 0-3 o-8 0-8 Throttle valve hv.) #120 = #125 Pilot j Pa.) #15 #10 #125 ‘Starter jet (G8) #478 = = Pilot screw PS.) PRE-SET nneee ae (1-% turns out) Throttle cable play O5—1.0 mm (6,02—0.04 in) CARBURETOR ‘SPECIFICATION TEM 02 and 22 a 22,24 £18 | £-22-Utype Carburetor type ‘MIKUNT = MIKUNI MIKUNI BDST36SS BpST33ss_|_SDST36SS Bore size 36 mm = 33 mm 36 mm 2iEF ies 21EL 218K 1200+ 100 | 1 300 100 = a simin rnin Float height, 6.92 1.0 mm (0.27£0.04 in)May-25-2022 @3:26P FROM: TO: 18478730197 P:8 117 AFGOORT (‘96 MODEL) ‘SPEGIFICATION rem £02 and a £:22,24 E18 E-22-Utype Main jet (Mo #1125 = #110 #120 Main air jet (MAJ) |wiae0.6 mm] 2243:1.0 mm o's ami, ocr Jat needle WN] $D44-3rd = BE93-4th | 6D44-2nd Needle jet Wsj{ 0-9 = 0-8 = Throtie valve hv] #128 = #120 #125 Pilot jet PJ] 812.5 = #10 12.5 Storter jet 1G.S.)|__#47.5 = = = Pilot screw (P.S.)| PRE-SET oa a PRESET 1-¥e turns out) (1. turn out) Tirotle cable play O5—1.0 mm (0.02—0.04 in) ELECTRICAL Unit: mm fin) TEM SPCIFICATION NOTE Ignition timing 4 B.1.D.C. below 1 600 r/min. E-18,33 7 B.T.D.C. below 1 500 r/min. Others Firing order 1-2-4-3 ‘Spark plug NGK; CROE Type ND: U27ESR-N ca 07-08, (0.028—0.032) ‘Spark performance Over 8 (0.3) at 1 atm. ‘Signal coll resistance (Black—Green) Tester range: Approx. 135-200 0 {x 100 9) Ignition coll resistance Priman @ tap— © tap Tester range; tana Approx. 2.4—3.2 2 x19) Plug cap—Plug cap Tester range: [Secondary Approx. 30-40 ko 1 ko} jenerator Sip ring O.D. [Limit 14.0 (0.55) ND Brush length Limit 4.5 10.18) Generator Max. output The rotation of Approx. 405 W at 5 000 r/min the generator Regulated voltage ‘Above 13.5 Vat 5 000 r/min. ‘Starter motor ‘Commutator : raat Limit: 0.2 (0.008) NO Storter relay resistance: 3-59 Battery —_| Type designation YTX9-8S Capacity T2V 26.8 kC (8 AbI/TO HR Standard 20 68° electrolyte 8.G. 1.320 at 20°C (68°F) Fuse size ight LHL 15 A Headiight | +e Turn signal 15 A ignition TOA Taillight 10 A ‘Main 30 ATO: 18478730197 Po RFGOORT (96-MODEL) 11.8 WATTAGE Unit: W ‘SPECIFICATION ue £.03,24,28,33 The others Headlight HI 60 = Lo 55 = Position light 4 Taillight 5 = Brake light 21 = Turn signal 2164 7 Tachometer light 172 = Speedometer light L7x2 = Turn signal indicator fight 34 = High beam indicator light 3.4 = Neutral indicator light 34 = Oil pressure indicator ight 34 = Fuel level indicator light 4 a License light = Engine coolant temp. meter = light BRAKE + WHEEL Unit: mm (in) TEM STANDARD. TMi Riear brake pedal height eS Brake dise thickness poe vote = SF08 oS 5.0 = 02 45 eee (0.187 * 0.008) (0.18) Brake disc runout oaks {Front & Rear) . Master cylinder bore ae ae a 12.700—12,743 ie (0.6000—0.8017) Master evlinder piston diam. | prone oes 4884, 12.657— 12.684 a eat (0.4983—0.4993) Brake caliper 25.400—25.450 cylinder bore een {1.6000—1.6020) ith e 25.400—25.450 Trailing (1,6000—1.6020) 38. 180—38,266 a (1.6031—1.5061) ee — Front 25.335 25.368 1MAY-25-2082 @3:26P FROM: TO: 18478730197 PH18 11.8 RFGUORT (96-MODEL) TEM STANDARD OMT Wheel rim runout : 2.0 (Front & Rear) ine! (0.08) 2.0 Radial oes Wheel axie runout 0.28 Front 40.010) 0.25 Led 40.010) Tire size Front 720770 ZA17 — Rear 160/60 2817 — Tire tread depth TS Front A 2.0 Bee (0.08) SUSPENSION Unit: mm {in) TEM STANDARD TMT NOTE Front fork stroke 120 (4.7) Front fork spring free length 390 = (15.4) Front fork oll level 32 (3.6) Rear wheel travel 7130 (5.1) ‘Swingarm pivot shaft runout 03 (0.01) FUEL + OIL + ENGINE COOLANT TEM ‘SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 85 pump octane ( £3 |) or 91 octane or higher ated by the resdarch method. Gasoline containing MTBE (Methyl Tertiary | £-03,33 Butyl Ether. less than 10% ethanol, or less than 5% methanol with appropriate cosol- vents and corrosion inhibitor is permissible. Use only unleaded gasoline of at least 87 pump octane ( 4° method) or 91 octane | £28 br higher rated BY the Research Method. Gasoline used should be graded 86-95 oc- tane or higher. An unleaded gasoline is | The others recommended. Fuel tank including reserve T60L (4.2/3.8 US/imp gal) iii 7.0L (4.5/3.7 US/imp gal) nel other reserve 4.0L (1.1/0.9 USfimp galMAY-25-2002 @3:27P FROM: TO: 18478730197 ArsoonT TEM ‘SPECIFICATION NOTE Engine oll type SAE 10W/40, API SE, SF or SG Engine oil capacity 3 000 mi ‘Change (3.2/2.6 US/mp qt) '3 300 mi Filter change | (3.5/2.9 US/Imp qv) 3 900 mi Overhaul (4.1/3.4 US/imp qt) Front fork oil type Frok oll #10 Front fork oil capacity 503 mi (each leg) (17.0/17.7 US/imp 02) Brake fiuid type DOT 4 Engine coolant type water only, 1e/coolant compatible with mixed with distilled e ratio of 50:50. Engine coolant including reserve 2 460 mi (2.6/2.2 US/Imp at) TIRE PRESSURE [E-03,33 markets) COLD INFLATION |__ SOLO RIDING. DUAL AIDING TIRE PRESSURE [kPa _|kgicm2]_psi_| kPa _|kg/cm4|_psi FRONT 225 | 2.25 [33 | 250 | 2.50] 36 REAR 250 | 2.50] 36 | 290 [2.90 | 42 TIRE PRESSURE [The other markets] COLD INFLATION |__ SOLO RIDING. DUAL RIDING TIRE PRESSURE ["kPa |kg/em®|_psi_| kPa _|kg/cm®| psi FRONT 250 | 2.50 | 36. | 250 | 2.50 | 36 REAR 250 [2.60] 36 | 290 | 2.90 [42MAY-25-2082 @3:27P FROM: TO: 18478730197 11-11 REGOORT (96-MODEL) SERVICE INFORMATION REAR BRAKE AND TORQUE LINK ROD 5 3| 3| 2 a ® ® © “oO £23 © ‘© J Pistonicup set Reservoir tank hose Brake hose J Pat ® Inner shim Outer shim © Pivot shattMAY-25-2082 @3:29P FROM: TO: 18478730197 Pit RFGOORV ('97-MODEL) CONTENTS: ‘SPECIFICATIONS 12- SERVICE DATA ~ 1 12-2 NOTE: The specifications and service data ere the same as those of the ‘96-MODEL.MAY-25-2082 @3:29P FROM: 12.1_AFSOORY (87-MODEL! TO: 18478730197 121 REGOORY (87-MODEU SPECIFICATIONS DIMENSIONS AND ORY MASS Overall tength Qverail width. Sveratl “hetghe Wheelbase Ground eiearance Seat" height Biy mass sxone Vohie’ cisarances” iW ex of evlinders Air cleaner Starter system 220 Tbseadion system. « Drive chain, se eeeeeeee cuassis Front suspension eer suspension Front suspension stroke Rear suspension Seater Steering a ime saab Front bak Rear brave. Frome es ste Fee Heactignt ‘Tum signe! inceator ght Oi predaure Ingieator Nght. uel indicator Hoht a amo. meter Eg. gaacmes Flat tenn, including reserve Engine ol, of ena naine ol, of chonge ser fier change cegna onse From fork of. = 818, 22 Otners Four-soke, liquid-cooled, DOHG, TSCC {0'40=0.20 mim {0.040.008 in} 8:20-8:38 ron 1.0080.012 5.9 mom (2.559 In) 18.2 men (1.780 in £388 em" (96.6 cu. i) 20°" ‘ BOS139. four... £18 SDST38, four |. Others Non-woven face element Garon meter Wet mutilate type ed conatart moth i 8 OF asia)... £18 ‘Otners RieSOMPOR, 18 tke “eloscosic, col sorin, oll damped, sing preload adjustable Lae gg sen asd 74a scion, camping 120 mm 18.7 im 430 mm (6.1 in) 2° 103 mm (4.06 int 08 32m 110.5 1) Bick’ brake, twin isk Brake! $20/70017 seo/e02e17 Electronic igaition (Transistorieed) i°B'110.c8 below 1800 rim» E18 2 BEDE. below 1800 min | GK CASE of NIpPONDENSO U27ESrN 13V 28,8KC (8 ANI/1O HR ‘Bsephaae AC: gonerater iShsnos 5/108, sew WV 6a 1BV awe excepe E28 1BV 214) 1By Bw iv 2hw2 yegezeze® itis 2232355 88 ‘ewayMayY-25-2022 @3:29P FROM: TO: 18478730197 P33 REGOORV (97.MONEL) 12:2 SERVICE DATA VALVE + GUIDE Unit: mm in) TEM ‘STANDARD Tui Valve diam. in 25.5 (1.60) 22.5 bata (0.89) Valve lift £04 and x} others (0.33) IN. ay a (0.26) Saat E04 ond 78 eae others (0.31) Ex, G1 cae (0.24) Se Tappet clearance (when cold) 0.10-0.20 he mt (0,604—-0.008) 7 0.20—0.30 : {0,608—9.010) Valve guide to vaive stem ii '0.020-0.047 clearance a (0,0008—0.0019) 7 0.030—0.057 : (0,6012—0.0022) Valve stem deflection 035 ee —_ (0.014) Vaive guide 1.0. 4,500~4.512 ana {0.1772—0.1776) Valve stem 0.0. 7 4.465—4.480 (0.1758—0.1764) x 4A55—4.470 z (0.1754—0,1760) Valve stem runout 0.05 eee (0.002) Valve head thickness 0.5 IN: & EX. ioae Valve seat width 99-11 ee (0.035—0.043) 0.03 ea (0.001) Valve spring free length 43.0 (IN. & EX.) (1.69) Valve spring tension pe— ata (IN. & EX.) (41,0—47.2 Ibs) — at length 38 mm (1.5 in}MAY-25-2082 @3:29P FROM: TO: 18478730197 Pq 12.3 RFGOORV ('97-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm {ind TEM STANDARD, uMiT Cam height £04 | 36,312—36,368 36.02 2 (1.4296—1.4318) |_ (1.418) 34.542 —34.598 34.26 IN. | £1833 | (7.3699—1.3621) |_(1.948) 36.312—36.368 36.02 Others | (7.4296—1,.4318) |__(1.478) eo | ,35,902—35,958 35.61 (1.4136—1.4157 | _(1.402) 34.122—34.178 33.83 EX. | £18.33 | (7.3433—1.3456) | _ (1.332) 35,902—35.958 35.61 Others | (1.4135—1.4187 | __(1.402) Camsheft journal oll clearance (iy @ Ex. 0.032—0.066 0.150 ae (0.6013—-0.0026) (0.0059) ‘Camshaft journal holder 1.0. 22.012—22.025 ee (0.8666—0.8671) Camshaft journal 0.0. 21,959—21.980 chet (0.8645—0.8654) Camshaft runout ice ee eaen Can chain pin (at arrow 3") 73th pin — Cylinder head distortion 0,20 (0,008) CYLINDER + PISTON + PISTON RING ‘Unit: mm fin) TEM, ‘STANDARD Limit Compression pressure T 000—1 500 kPa B00 kPa 10-18 kglem@y (8 kg/em®) 142-213 psi 1 14psi Compression pressure 200 kPa eronce — (2kglem) 28 psi Piston to eylinder clearance 0.040-0.060 0.120 (0.0016 -0.0024) (0.0047) Cylinder bore’ €5.000—65.015 65.080 (2.5591— 2.8596) (2.5626) Piston diam. 64.945--64,970 areas (2,5569—2.5579) aes Measure at_15 rm (0.6 in) from the skirt end.|_(2-5543) Cylinder distortion 0.20 (0.008) Piston ting free end gap 75 6.0 ast APPIOX. (0.23) (0.24) 8.0 6.4 ere lee APPFOX. (0,31) 10.25) Piston ring end gap tet 0.25-0.40 05 ia (0.010—0.016) (0.02) 0.25—0.40 0.8 ae (0.010—0.016) (0.02)MAY-25-2082 @3:29P FROM: TO: 18478730197 PS RESOORY ('97-MODEL) 12-4 TEM ‘STANDARD TMT Fiston ring to groove clearance| —_ 0.18 ce en (0,007) 0.18 2nd (0.007) Piston ring groove width 0.83—-0.85, jeans ab (0.032—0.033) 0.82-0.84 oa (0.632—0.033) roy 7.51=1.53 i {0,059—9.060) Piston Fing thickness 0.77-0.79, cae * at (0.630—0.031) 0.77-0.79 oa (0.030-0.031) Fiston pin bore 16,902 -16,008 76.030 (0.6311) Piston pin 0.D. 15. SB 16.000 15.980 (0.6298—0.6299) (0.6291) CONROD + CRANKSHAFT Unit: mm (in) TEM ‘STANDARD Timi Conrod small end 1.D. 16.010—16.018 16.040 {0.6303 0.6306) (0.6315) Conrod big end side clearance 0.10—-0.20 0.30 (0.004—0.008) (0.010) Conrod big end width 20.95—21.00 (0.825—0.827) Crank pin width 21.10—21.15 (0.831—0.833) Conrod big end oil clearence 0.032—0.056 0.080 (0.6013 —0.0022) (0.0031) rank pin 0.D. "33.976 34.000 (1,3376—1.3386) Crankshaft journal oil clearance] 0.020—0.044, 0,080 (0.0008—0.0017) (0.0031) Crankshaft journal 0.D. 33.976 34.000 (1,3376—1.3386) Crankshaft thrust clearance (0.055—0.110 (0,6022—0.0043) Crankshaft thrust bearing 2.425—2.450 thickness Right side {0.0955 —0.0965) z 2.350—2.500 heer (0.0825-0.0984) Crankshaft runout 0.05 it (0.002)MAY-25-2082 @3:3P FROM: TO: 18478730197 2s nesoonv raymone OIL PUMP Trem STANDARD, Oil pump reduction ratio 1,898 (75/43 x 37/34) Oil pressure (at 60°C, 140°F) ‘Above 300 kPa (3.0 kg/em?, 43 Below 600 kPa (6.0 kg/cm?, 86 psi at 3 000 rimin, CLUTCH Unit: mm (in) TEM, ‘STANDARD. LIMIT. ‘Clutch lever play Drive plate thickness 2.12-2.28 1.82 (0.683—-0.090) (0.072) Driven plate distortion 0.10 40.004) [Gineh Spring free length 47.5 THERMOSTAT + RADIATOR + FAN TEM STANDARD TMT Thermostat valve opening 74.5—78,5°C temperature (166.1—173.3°F) Thermostat valve lift Over 7 mm (0.28 in) at 90°C (194°F) Radiator cap valve opening pressure 110 kPa (1.1 ka/cm?, 15.6 psi) Approx. 105°C (21°F) Cooling fan therme- | on switch operating ‘temperature OFF Approx. 100°C (212°F) Engine coolant temperature gauge resistance (reer Approx. 153.9 2 (ares ee eee oa, Approx. 27.4 9 eae, ‘Approx, 16.1 2 TRANSMISSION + DRIVE CHAIN Unit: mm {in} Except ratio TEM ‘STANDARD LIMIT Primary reduction ratio 1.744 (75/43) Final reduction ratio E-03,18,33 3.071 (43/14) oo [The others 3.000 (42/14) —— Gear ratios Low 3.142 (44/14) — 2nd) 2.058 (35/17) Eom ‘3rd 1.650 (33/20) a 4th 1.428 (30/21) — 5th 1.260 (29/23) oo Top 1.120 (28/25) —MAY-25-2082 @3:3P FROM: FROM: TO: 18478730197 Pi? REGOORY (97-MODEL) 125 Trem STANDARD. air Shift fork to groove clearance 0,10-0.30, 0.50, (0.004—0.012) (0.020) Shift fork groove width 7 ae Shit fork thickness saat Drive chai Type RKEOMFOZT ==] Links 708 links, ENDLESS — a 20-pitch lenath —_ ive Drive chain slack 30-40 aeaee (1.2-1.6) Gearshift lover height 70 ie (2.8) CARBURETOR SPECIFICATION eM Ss USA £03, U.S.A. (Calif. modei) cee Carburetor type TIKUNT BOSTSESS|MIKUNI BDST39SS|MIKUNI BDST36SS Bore size 36 mm 33 mm, 36 mm LD. No. 2166 26H 2iEN idle t/min- {B00 100 rmin | 7 50s 100 eimin | 1 200 100 vimin Float height 6.94 1,0 mm (0.270,04 int Main jot Wd) #25 #107 wi28 Main air jot MAL) wise. 0.6 min, 0.7 mm 0.6 mm eee oo Tet needle ND EST E08 5D44-3rd Needle jet (Ned) 0-9 a8 O89 Throttle valve hv) #120 = #2 Pilot jet (Pd) #15 #0. #125 Starter jet (6S) #475 = = Pilot screw eS) = PRESET PRE-SET (1% turns out) Throttle cable play O5— 1,0 mm (0.02—0.04 int CARBURETOR ‘SPECIFICATION al item E02 and L o2in £-22,24 E18 | €22-Utype Carburetor type MIKUNI = ‘MIKUNI MIKUNI BOST36SS. apst3ass_| BDST3ess Bore size 36mm = 33 mm 36 mm 1.D. No. 21EF Zid 2HEL ZiEK Tale r/min. 72002100 | 1 300 100 ce = ries rienin Float height ESE 1.0 rom (0,272 0.04 in)MAY-25-2082 @3:3P FROM: TO: 18478730197 12.7_RFSOORV ('97-MODEL) ‘SPECIFICATION De ae E.22,24 E18 Main jet (Wi [ #1125 = #110 in alr A.J.) | #184: 0.6 mm Main air jet MAS 184 0.8 mm ze ae Gat Jet needle WN] 5D44-3rd = BEOS-ath ‘Needle jet (N.S) 0-9 = 0-8, Throttle valve Th.v.) [#125 = #120 Pilot jet (ad) | #128 = #10 ‘Starter jot 1G.S) [#475 = = Pilot screw (P.S.) | PRESET = a \1-ve tums out) Thigttle cable plat ELECTRICAL 0.5—1.0 mm (0.02—0.04 in) TEM ‘SPCIFICATION Ignition timing @B.T.D.C. below 1 500 r/min. 7° B.T.D.C. below 1 500 t/min. Firing order 12-405 NGK: CROE eennee Type ND: U27ESR-N 0.7-0.8 Gep (0.028—0.032) ‘Spark performance ‘Over 8 (0.3) at 1 atm. Signal coil resistance (Black— Green) Approx. 135-200 2 ignition coll resistance @ tap— © tap Primary Approx. 2.4—3.2 @ Plug cap—Plug cap econ Approx, 30-40 ko Generator Slip ing 0.0. Limit: 14.0 (0.55) Brush length Limi 4.5 (0.18) Generator Max. output Approx. 405 W at 5 000 r/min The rotation of Regulated voltage Above 13.5 V at § 000 rmin. eer cone: Limit: 0.2 (0.008) Tiarter relay resistance: 3-50 Battery | Type designation YTX9BS Capacity, 72V 26.8 kC (8 AnI/10 HA een rah. 1.320 at 20°C (68°F) Fuse size cone LH! 5A Headlight LHL 13 A Tum signal 15A Ignition, TOA Taillight OA Main 0ATO: 18478730197 Po RFBOORY ('97-MODEL) 12.8 WATTAGE Unit: W ‘SPECIFICATION. ea £03,204, 28,33 ‘The others Headlight HL 60. ae Lo 55 ae Position light 4 Taillight 5 oe Broke light 2x2 = Tum signal li 2x4 = Tachometer light TIx2 = ‘Speedometer tight V7 x2 fa a] Turn signal indicator light 34 = High beam indicator light 3.4 = Neutral indicator light 34 = Oil pressure indicator light 3.4 oe Fuel level indicator light 3.4 Rl License light s = Engine coolant temp. meter me light ie Ee BRAKE+WHEEL Unit: mm Gin) TEM. ‘STANDARD ‘LMIT Rear brake pedal height ee Brake disc thickness 4.5 + 0.2 4.0 noes (0.177 * 0.008) (0.16) 5.0 = 0.2 4.5 eat (0.197 = 0.008) (0.18) Brake disc runout 0.30 (Front & Rear) (0.012) Master cylinder bore Front 308 Sota 12.700=-12.743 __ Lisal (0,8000--0.5017) ‘Master cylinder piston diam. Front nae zs (0.4983 —' ) 12.657—12.684 Lia (0.4983—0.4993) Rast [om pare | aaa idl 25.400—25.450 a {1.0000—1.0020) 38.180—38.256 a (1.6031— 1.5061) a Ege [awe | | eaeeicdaseh_— | ling (25.335— 25.368 (0,8974—0,9987) aes 38.098—38,148 fe (1,5000— 1.5019) aaaTO: 18478730197 P18 TEM, ‘STANDARD TMI Wheel rim runout i ase 2.0 (Front & Rear) Axial (0.08) 2.0 Liceenal ects (6.08) Wheel axle ranout 0.25 ee fom (0.010) 3 0.25 eae (0.010) ‘Wheel rim size Front Styx MT3.50 — Rear S17 MT4.50 = Tire size Front 120/70 ZR17 = Rear 160/60 2R17 = Tire tread depth _—_ 16 mon (0.06) 2.0 oe (0.08) SUSPENSION Unit: mm (in) TEM, “STANDARD. TMT NOTE Front fork stroke 120 (4.7) Front fork spring free length 380 3 - 6.4) Front fork oil level 92 (3.6) Rear wheel travel 130 6) ‘Swingarm pivot shaft runout 03 (0.01) FUEL + OIL+ENGINE COOLANT TEM SPECIFICATION ‘NOTE Fuel type Use only unleaded gasoline of at least 85 pump octane ( 85!) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary | £-03,33 Butyl Ether), less then 10% ethanol, or less. than 5% methanol with appropriate cosol- vents and corrosion inhibitor is permissible. Use only unleaded gasoline of at least 87 pump octane ( 5" method) or 91 octane £28 br higher rated by the Research Method. Gasoline used should be graded 85-95 oc- tane or higher. An unleaded gasoline is | The others recommended. Fuel tank including reserve 16.01 nas (4.2/3.5 USiimp gal) aie The others {4.5/3.7 US/Imp_gal) i reserve 4.0L {1.1/0.9 US/imp gal)TO: 18478730197 Pri RFGOORY ('97.MODEL) 12.10 TEM SPECIFICATION NOTE Engine oll type SAE 10W/40, API SF or SG Engine oll capacity ‘3 060 mi : Change (3.2/2.6 US/imp qt) 3.300 mi Fixer change | __ (3.5/2.9 US/imp qt) 3 900 mi Overhaul (4.1/3.4 US/imp at) Front fork oll type Fork oll #10 [Front fork oil capacity 503 mi teach leg) (17.0/17,7 US/imp 02) Brake fluid type DOT 4 Engine coolant type ‘Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50:50. Engine coolant including 2 450 mi reserve (2.6/2.2 US/Imp at) a TIRE PRESSURE [E-03,33 markets] COLD INFLATION [__ SOLO RIDING DUAL AIDING: TIRE PRESSURE [kPa _[kgicmé]_pat| kPa [kglem’l psi FRONT 226 | 2.25 | 33 | 250 | 2.50 | 36 REAR 250 [2.60] 36 | 290 | 2.90] 42 TIRE PRESSURE [The other markets] : COLD INFLATION [SOLO RIDING DUAL RIDING TIRE PRESSURE [kPa _[ka/em®]_psi_| kPa |kg/em4[ pst FRONT 250 | 2.50] 36 | 250 | 2.60] 36 REAR 250 | 2.60] 36_| 290 [2.90] 42MAY-25-2082 @3:3eP FROM: Out Rep, Out Ry. yw ae tig, Ss ip C Performance Performance Motorcycle Parts Motorcycle Parts 440-985-3853 440-985-3853 € Mh OUT RACING po PURER, Performance Motorcycle Parts 440-985-3853 Prepared by SUZUKI MOTOR CORPORATION Morte See Dearne € 3rd Ed. April, 1997 Ist Ed. Suly, 1993 Part No, 99500-35033-03E Printed in Japan : . t . AY Out Recs, Out Rez, 7 Performance Performance ¢ Motorcycle Parts Motorcycle Parts 440-985-3853 440-985-3853 Mh OUT RACING FORGE, Peiformance Motorcycle Parts 440-985-3853 CcMAY-25-2082 @3:3eP FROM: Prepared by SUZUKI MOTOR CORPORATION Motorcycle Service Department 3rd Ed. April, 1997 Ist Ed. July, 1993 Part No, 99500-35033-03E Printed in Japan TO: 18478730197 PileFIG.1 FIG.L ( B 2) Cri INDER HEAD COVER REFNO. PART NO. 1 ALL7i-3LE00 2 12173-2100 3 111 78-17E00 a 09106 07009 5 09161-11008 6 09206-08001 ? 11173~31E00: 6 LLL7/=.7E0): 9 01550-06253 10-1 42401-17811 10-2 Loud 17812 10-3 11401-17813 RFGOORT E3. DESCRIPTION _. COVER, cylinder need CASKET, head cover ‘to.1 GASKET, head cover No.2 BOLT (L:5.5) WASHER: PIN COVER, breather GASKE), brvather cover BOLT GASKET ST GASKET SET GASKET SET model model S model B2FIG.2 ( 8 3) CYLINDER HEAD REFNO. PART NO. DESCRIPTION REMARKS 1-1 11100-21£00 HEAD ASSY, cylinder 1-2 LLL00-21E10 HEAD ASSY, cylinder JLLIS-17E70 GUIDE, valve 09103-06165 .BOLT (6x45) 09206-08001 .PIN LLLAL- 18601 GASKET, cylinder heed Oe2711-11169 PIN 01550-06303 BOLT 09103-10272 JOLT (110x160) 09160-10062 WASHER 07120-08163 BOLT, ofl gallery Ex 09168-08015 GASKET 11131-47600. PITE, of 09103-6026. BOLT (6x39) 08322-01063 WASHER 09882-00058 SPARK PLUG (NGK, CRIE) 09882-00059 SPARK PLUG Re rer edoeaKNHNHES ene ak ReeFIG.3 ¢ B+ 4) CYLINDER REFNO. PART NO, DESCRIPTION 1-1 ~ 1210-21610 CYLINDER 1-2 12210-2181). CYLINDER 09280-71004 +O RING 11241-21200 GASKET, cylinder 01421-06205 ‘STUD BOLT mou lh R 01421-06203 STUD BOLT wool S/T (08316-10063 wT 08211-11169 PIN 17415-14300 GOLT, cylinder drain 09168-08008 GASKET 11281-21600 WHOSE, oll RH 14282-21600 HOSE, o11 LH 11284-17600 BOLT, ol! hose union 09168-08016 GASKET 11285-32000 BOLT, oll hose union 09161-10009 GASKET15 15 181518 15 15 MFM. PART_NO. 1-1 11300-17808 rate 1-2 11302-46891 1-3 11.02-a6892 2 ova06-19008 3 04211-09129 4 09103-0616" 161719 44 09103-06067 23. Yo 37 so 7 5 09103-09007 B35 WS 6 09103-09008 24 a eG ? 39103-09009 8 09103-09010 9 09108-09001 10 07130-06753 u 07130-00303 R 07130-08603 dD 07130-08003 la 01550-08603 as 01350-06353 16 01350-06403 01550-06003 lo 01550-06503 v 01350-06653 n 07130-06259 2 07130-06353 2 07130-6803 a 07130-06303 2a 07130-06603 23 09103-06062 26 09168-06018 264 09168-10031 27 09168-00016 aa 09280-04008 a ov2as-18002 » 09493-24010 RFGOORT E3 FIG.4 ( GB 5) CRMKCASE CRUNCASE SET CRANKCASE SET CWMRCASE SET PIN PIN BOLT (6105) BOLT (6x103) BOLT (9x80) DES. MIPTION CHAIN, Cam shaft drive CHAIN, cam sheft drive GUIDE, cam chat: No.1 @ULOE, cam chain No.2 SOPew TENSIONER, cum chain CUSHION QUINE, cam chain No.3 QUIDE, cam chain No.3 BOLT BOLT WASHER ADWSTER ASSY, tensioner PUG GASKET SPRING GASKET, edjuster BOLT (6x23) BOLT (6x22) av DNR ee eee NEN ee model kodel S/T model & model S/T model R model S/T model R/S wodel TFIG.11 ( C- 2) CARBURETOR RERNO. PANT NO 1-1 13201-21€80 1-2 13701-21660 iy 13201-21£50 1+ 13201-21EHO ZL 13202-21660 2-2 13202-21EG0 2-3 13202-2150 2-4 13202-21EH0 31 13203-21640 3-2 13203-21660 boo) 13203-21650 3a 13203-21€H0 aL 13204-21£40 4-2 17204-21660 as 13204-21650 4-4 19204-21EH0 ? Azasy- TIEN 6-1 96321-21087 6-2 08321-01087 7 13553-21E10 8 13557-47070 9 13573-21£10 10 13573-21E00 al 13550-21610 12 13550-2100 13 2112-75: 53 aT) 08310-00083 re) 13550-21E20 16 13553-21£00 Lek 13502-17E20 1-2 13502-3300 18-1 13507-17000 18-2 13507-17001 RFGOORT E3 DESCRIPTION CARBURETOR ASSY, CARBURETOR ASSY, CARBURETOR ASSY, CARBURETOR ASSY, UH LH ut CARBURETUR ASSY, ‘CARBURETOR ASSY, CARBURL TOR ASSY, CARBURE "UR ASSY, (CARBURETOR ASSY, CARBURETOR ASSY, CARBURETOR ASSY, CARBURETOR A:SY, CARBURS.[OR ASSY, CARBURETOR ASSY, CARBURETOR ASSY, CARBURETOR ASSY, 2222 SEER EERE SHAFT, throttle LEVER, throttle «LEVER, throttle SHAFT, throttle -SHAFT, throttle SHAFT, throttle -COVER, diaphraga -COVER, diaphraga «DIAPHRAGM «DIAPHRAGM an meee Peer ee Cd REMARKS: model R model S/T (CALIFORNIA ONLY, model R (CALIFORNIA ONLY model S/T model R model S/T CALIFORNIA ONLY, model R CALIFORNIA ONLY model S/T model R model S/T CALIFORNIA ONLY, mocel R (CALIFORNIA ONLY model S/T model R model $/T CALIFORNIA ONLY, model R CALIFORNIA ONLY model S/T RH HLM, model R ML,MR,model S/T MR SeFRE aR CALIFORNIA ONLY model R model S/T C27oy Row iwe) 08 RRANECAS 7 1b cove FIG.L1 ( C- 3) CARBURETOR RERNO. PART NO. iy 13501-18€00 a 13417-12000 a. 13382-42000 2 13994-40020 ” 13567-87010 2 13382-46030 re 13574-32000 26-1 13983-21E 10 26-2 13383-21610 26-3 1398)-21E0 ar 13251-33000 ru 13932-05010 2-1 G3a94~00810 29-2 09494) ~008 54 B-3 (09494-00814 Ds 09494-00853 wo 13331-21E40 n 13602-06620 2 13294-35000 x” 13417-26000 MM 13432-47090 By 13220-21600 M-1 (09491-22025 4-2 09491-22025 %-3 09491-21020 1 13385-33020 M-2 13385~21E00 x” 13418-17010 »” 13418-17000 «0 13411-05320 RFGOOKT £3 DESCRIPTION SWALYE, piston SPRING RING CLIP, needle RING WASHER -RING NEEL. Jot (5697-1) «NEEDLE, Joi (5E97-1) «NEEDLE, Jot (5695-1) 0 RING WACKER, «ET, needle (0-9) oT, needle (0-9) ET, needle (0-8) JET, needle (0-8) -RING SCREW «0 RING «SPRING WASHER, HOLDER, Jot SET, main (112.5) ET, main (112.5) KT, main (107.5) -HOLDER, jet. -HOLOER, Jet -HOLDER, guide .CAP, starter -PUUNGER ASSY av > epee eer een pee eee Pee Hee ee PD. >> pee U4, RA CALIFORNTA ONLY, model. R CALIFORNIA GHLY model S/T model R model S/T CALIFURNIA ONLY, model FP CALIFORNIA ONLY model S/T CALIFORNIA ONLY,mode) CALIFORNIA ONLY model S/T CALIFORNIA ONLY UPON.FIG.11 FIG.11 ( C+ 6) CARQURETOR = 2 EEN. PART NO. bEscar al-1 09493-60004 «KT, main air (0.6) ai-2 (09.493~70009 ET, main air (0.7) al-3 09499-60004 eT, main air (0.6) 2-1 09493-29002 HET, pilot air (1.43) 42-2 09493-27002 RT, pilot alr (1.33) a} 13250-21£00 -FLOAT/NEEDLE VALVE ASSY “” 13331-06C20 RING “a5 13376-84110 FILTER 46-1 09492-15017 JET, pilot (25) 6-2 09492-10902 wT, pilot (10) “7 09491-47001 «ET, starter (47.5) ae 13258-33C00 SEAL “9 13295-2990" -O RING 30 13791-29900 ASHER Bat 13268-47070 SPRING 13279-47070 «SCREW, pilot (1.1/4) 13602-0510 13508-17000 13671-33600 13251-06010 2361-51010 13402-05148 13627-2100 13627-31£00 13603-05108 02122-05103 02112-05127 13247-13400 13374-44080 19557-07000 weer ere eer er Oe ee ee ee eer eee eee eeFIG.12 “Sse 2, ) 10 FIG.A2 ( C= 3) CAMBUNETO® FITTINGS: Ri). PART NO. 1 13427-38900 2 13267-21000 3 13271-33000 4 13612-21600 3 19331-21E00 ‘ 13683-21600 7 13331-21£20 a 19331-21690 3 13499-17000 10 13413-3.£00 M-2 13606-00A10 Ne? 08322-0105) 12-1 13607-33000 12-2 08310-00053 yy 13573-06010 M 13413-06010 a 13624-33000 ty 13683-21610 v 13683-34C00 ty 13685-33000 » 13612-21£10 a 13683-21E00 a 13331-21E10 2 13673-48800 B-1 13606-06000 23-2 (083-2-0106) ma-1 13607-06000. 2a-2 08310-00063 3 13267-46800: “6 13271-44800: 7 13268-96110 2 13685-21E10 2-1 13509-3300 29-2 09280-10005 x” 13683~21E30 RFGOORT £3 DESCRIPTION WASHER ADNSTER ‘SPRING eur RING NIPPLE. RIS JOINT BRACKET ASSY HOSE (1D; 9e0):13) 2 a Ree ewe ee Re RR RE RE NER ENR RE NE NEN eee model R/S model T model R model S/T model A/S. model T model A/S model T model A/S aodel T CALIFORNIA ONLYFIG.12 ( C+ 6) CARBUNETOR FITTINGS ewFIG.13 FIG.13 (C= 7) ATR CLEANER F.NO.__PART NO, DESCRIPTION 1-1 13700-21£00 CLEANER ASSY, air 1-2 13700-21E0% CLEANER ASSY, air 13700-21E0) CLEANER ASSY, air 13780-21E00 FILTER, air 13740-21E00 .CAP, air cleaner 02142-05164 02142-05167 13891-17600 43881-Z1E00 09402:.58207 138390-21E00 13824-48810 09401-16401 13870-21428 TUBE, ‘train 13024-18910 « CLIP 13877-38000 + STUPPER, drain 13870-21628 TUBE, drain 13789-00020 ~ FILTER, drain 43872-00800 CAP, Lube drain 13824-00800 CLIP 09401-13409 Cur 13783-21£01 FILTER, cerb air,No.1 13784-21£00 FILTER, carb ait,No.Z 13784-2101 «FILTER, carb air,No.2 13835-21£00 TUBE, carb air R 13836-21£00 -Tume, carb air L 13824-48810 CLIP Ue01-16401 CLtP (09404-06426 CUM, drain tube 09404-06433 CLAMP, drain tube 02142-0612) SCREWFIG.14 FIG.14 ( C~ 6) MUFFLER (model A) REENO. _ PART NO. 1 14100-21600 2 14181-17€00 3 07130-08253 4 14771-07000 > 01530-08403 6 14910-2109 7 01500-0000) 8 OP 160-08002 , (08321-0108) 10 09320-12008 1 09180-00152 2 14770-21600 b 01550-08163 Cy 01530-08457 Bb 08316-1000) 16 09160-08106 ed 09320-12049 18 09180-08156 PIPE, exheust fH GASKET, exheust pipe Bou CONNECTOR, muffler BOLT Booy, muffler BOLT WASHER (8.5"2911.6) LOOK WASHER: CUSHION ‘SPACER GRACKET, muffler BOLT BOLT wut WASHER (8. 1x33x1.6) CUSHION ‘SPACER Refer to FIG.L4A(C-9) for model S/T @DORT E3 er 1 a 6 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 Waitin CiLieee o SeinGing ane q CeFIG. 14 A Te aane tuven BEF.WO. PART WO. DESCRIPTION __ tel FIQ.1@AC C- 9) MUFFLER (model S/T) 14100-21660 1aL00-21661 1410) -17E00 07130-08253 14181-31E00 07106-08132 14310-31E80 OPLle-00152 09920-12068 09100-08152 14770-31£00 01530-08163 01530-08097 0361-23506) 1960-08106 9320-12009 09100-06156 PIPE, extwust PIPE, exhaust (GASKET, exhaust pipe eOLT GASKET, muffler joint COLT, muffler joint e007, muffler oor (CUSHION ‘SPACER GRACKET, muffler ear oor UT WASHER (6.133x1.6) (CUSHION SPACER| ee FIG.15 FIG.19 ( 0-10) FUEL Pe er a 13100-21E01 PUMP ASSY, fuel 1 2 07180-06011 ‘SPACER. 2 3 09920-09009 CUSHION 2 4 0P116-06010 Bout 2 5-1 99934-70133~600 HOSE 1 6000370 model A/S 5-2 09954-70123~600 HOSE 1 6000380 model T 6 09951-16152-600 PROTECTOR 1 600336 Th (09801-12008 cup 2 model A/S 7-2 09001-11407 cur 2 model T ; cto RFGOORT £3FIG.16 F1Q.16 ( Go11) OLL COOLER - OTL FILTER ey SEEN. PART NO. DESCRIPTION REAAIKS P- L 16600-17800 COMLER ASSY, ofl 1 2 09280-44003 0 RING (0:3.1,10:6).95 1 2 3 16991-3900 NLT, ofl cooler union 1 a 16461-31600 WOSE, O11 cooler,water in 1 1 WATL-17801 MOSE, O11 cooleT,water out. 1 wodel A 3-2 MGATL-17€02 HOSE, LL cooler,water out 1 model s/t ‘ 08721-22955 WASHER a 7 (09401-13410 one 4 8 16510-06801 FILTER ASSY, engine ofl * 9-1 09808-06007 ane 1 wodel R 9-2 09800-06029 One 1 wodei S/T RFGOORT £3 CtFIG.17 FIG.L7 ( C-L2) WATER PUP an 1-1 17400-17200 PUMP ASSY, water 1 model R 1-2 17800-17801 PUMP ASSY, wa.er 1 model S/T z 17491-17600 DWPELLER, weter pump 1 3 OP 168-06025 CASKET 1 4 17470-06000 SEAL, mechanical 1 3-1 17461-3800 «OIL SEAL 1 model R/S 3-2 09263-10000 OTL SEAL 1 model T 6-1 17311-1700 «SHAFT, water pump 1 model FR 6-2 17311-17801 »SHAFT, water pump 1 model S/T Jol 08113-69010 «=. BEARING 1 model R 7-2 09262-10014 -BEARING (10276::3) 1 wodel S/T G+) «= 09262-13008 = BEARING (15x28x7) 1 model R 6-2 0262-12001 -BEARING (12x28x8) 1 model S/T ’ 17418-33400 0 RING 1 10 17435-73000 JO RIM 1 u 08331-01206 = .CIRCLIP 1 model 12 02112-0616) SCREW 2 bby 09100-06099 BOLT (ex13) 1 la 09164-06006 =. LOCK WASHER 1 us 17634-17601 = HOSE, water pump outlet 1 6 OPA01-26000 | CLAN L 1-1 9402-33502 ane lL model 17-2 OMO-30911 CL 1 model S/T 1s 09108-06117 BOLT 1 Pt 08316-10063 NUT 1 2 02112-06353 SOREW 2 c12 RFGOORT E3 erLaR. Me COOK: Tin gvciaee13-1 13-2 ot 15-1 15-2 16 Vv 18 FIG.18 ( D- 2) RADIATOR PART NO. 17710-21600 09116-06147 09100-0/004 17787-19800 99320-1205) 17761-21E00 177a0-21600 17740-21£01 01580-06163 17750-21£00 17750-21602 01550-98553 17800-21E01 17820-17E00 17801-05400 02112-08063 17770-21600 17801-85000 02142-05083 01550-06123 01550-06103 08316-10063 ‘RFEOORT £3 DESCRIPTION KATLATOR ASSY, water BOUT SPACER (6.510. 5x12) CUSHION, radiator upper QUSHION, rediator lower SPACER, rediator lower BRACKET, radiator upper BRACKET, radiator upper BOLT BRACKET, redietor lower GRACKET, redistor Lower BOLT FAN ASSY, rediator FAN ASSY BOLT (Max0.7) SCREW SHROUD ASSY, fan SCREW (M5x0.6) SCREW BOLT BOLT NUT RRR YY eR RR Rr ENR RR ER model R model S/T model R model S/T model R model S/T model R model S/TFIG.19 FIG.19 {0+ 3) RADIATOR HOSE REFNO. PART NO. DESCRIPTION 17790-12001 CaP, rediator,1.1 17791-32006 CONDUCTION, rediator 01550-0616) BOLT 17792-12000 BRACKET, conduction 01530-06103 SOT 17831-21602 PIPE, conduction inlet 17851-24000 MOSE, conduction inlet 17856-17850 HOSE, conduction inlet 09200-48005 =O RING (0:2.4,10:43.2) 17662-21E00 CONNECTOR, thermostat inlet 17670-32001 THERMOSTAT, water 01550-06203 eo 17851--21£00 WOE, radiates inlet 17852-17600 MCSE, redietor outlet L7d55-17E02 HOUSE, heed inlet Joint 17856-17650 MUSE, head inlet joint 0% 01-26408 CLAMP, water fo%@ No.1 (09002-33502 CUM®, weter hose No.2 O9007-38511 CLAMP, water hose No.2 0402. 30302 CUM, water hose No.3 (09602-32511 CLAMP, water hose No.3 17853-17600 HOSE, water pump inlet 17856-21E0u HOSE, heed out Let ‘17880-21602 PIPE, heed outlet 1517-06125 eat 01556-06123 = BOLT, cylinder/hesd pipe O9103-.06104 BOLI, cylinder inlet pipe 09103-06083 BOLT, cylinder inlet pipe 17860-21601 PIPE, cylinder side ‘17860-17£00 PIPE, cylinder side 17870-21601 PIPE, cylinder inlet 7890-210. UNION, hose Joint 17890-17601 UNICI, hose Joint 03200-19007 0 RING (D:3 2,10:17.6) Pewee ee ee Re EN RR RE NB eR Ne mam Cl FoF Puts mane. ror run 7FIG.19 FN. rd a 2-1 2-2 a 3 n 2 » de-1 M-2 » M1 2 FIG.19 ( D- 4) MAOIATOR HOSE PART KS. “Ws 50~ 30RD 4176@9~45000 ‘30476-17200 ‘51553-15380 17910-21600 17932-12000 09136-06072 17901-21£00 90) -06411 17982-31£00 4.7981-21£00 09407-22008 09407-18002 09407-18403 S7GOORT E3 en DESCRIPTION RERAAKS GVAK ASSY, water temperature SWITCH, tedietor fen CGHION, conduction pipe CUSHION, conduction pipe TAM ASSY, reservoir CAP, reservoir tank ‘SCREW (6x16) HOSE, reservoir tank inlet ap HOSE, over flow WE, ever flow ae AP an 1 L L L L L 2 L 2 L L 1 L L model A/S onde] T model A/S model T model R/S model TFIG. 20 FIG.20 ( D+ 5) SECUMD AIR (CALIFORNIA ONLY) 7. SOF Fain Candee S09 Puc Fam rv BEENO.__ PART NO. DESCRIPTION ___ RERAKS, — 1-1 18700-26001 CLEANER ASSY, 2nd air 1 model R/S: 1-2 18700-17003 (CLEANER ASSY, 2nd air 1 model T 2 01590-0612) mT 2 a 01547-06123 our 2 3 16750-21600 BRACKET, 2nd alr cleaner 1 4 10420-17810 WHOSE SET, 2nd alr No.2 1 5 18510-46600 VALVE ASSY, air switching 1 ‘ 09354-85853-600 HOSE, vacuum 1 36004300 ? 10430-48800 VALVE ASSY, 2nd eir reed 2 8 10731-17000 HOSE, 2D eit cleaner inlet. 1 9 18410-21810 HOSE SET, 2nd air No... 1 10 O90 L- 13415 ap t a 18410-21600 PIPE, 2nd eir No.1 2 wa 18420-21£00 PIPE, 2nd air No.2 2 b 16441 ~45000 GASKET, 2nd alt pips a pty 01421-06163 ‘STUD BOLT a Lb 08316-1006) wuT 6 RFGOORT £3 Tire Warrcta coos Coe haa has Te eve Tole et aves aa aFIG.21 ( O 6) cuuTCH ENO. PART N 21200-21041 09160-25067 09263-35017 7110-1 7EL0 9180-24012 OP167-25007 09164-25001 08211-25081 ‘OP160-25056. 21441-17610 21441-17610 210-1721 21451-17800 21451-17000 21843-21E00 21462-L7E01 09440-20020: OP116-O6161 09180-06198. 22771-21E01 23165-2i£00 23261-21E00 09263-15003 O9166-15005 09285-12002 (09263-10015 09763-15012 23271-17000 01500-06205 GEAR, primary driven (NT:75) WASHER SEARING wuT WASHER WHER, wave WASHER WAS: (25030K2. 5) PLATE, @rive (1:2.2) PLATE, clutch drive No.1 PLATE, clutch drive No.2 PLATE, driven,Wo.1 (1:2.0) PLATE, driven,No.2 SPACER, clutch plete OISC, pressure SPRING BOLT (6x80) SPACER (6. 2012x16) COM, generetor drive (WT A/6L) RACK, release PINION, release BEARING (15x28x2) WASHER (15. 5x28x1) OIL SEAL (12x22%9) BEARING (10x14x10) GEARING (15x2212) AFM, clutch release eourFG.22 FIG.22 ( D- 7) TRANSMISSION NO. PART NO. DES!RIPTION 1 24120-17810 2 24221-17600 3 (09380-27008 4 24231-17800 5 24251-17810 6 09301-28001 7 09380-27001 8 24261-17610 9 24362-17800 10 09167-27001 Al-1 (09262-25051 1-2 09262-25105 12-1 09990-62006 12-2 09390-62012 8) 09285-20006 ity 23116-2709) us ‘24741-2700 le 07172-06163 wr 09263-20069 18 (04221-07129 w 24131-17610 a 2@311-17E20 a (09300-22008 2 08711-20341 2 (08211-22341 aa 26321-17610 roy 09309-28003 » 3211-28381 a 09380-27001 8 24931-17602 a 24392-17602 » 09167-27001 3 09167-27002 32-1 24341-17602 322 24341-17603 RF6OORT E) COUNTERSHAFT (NT: 14) GEAR, 2nd drive (WT:17) CIACLIP GEM, Wath drive (NT:20/21) GEAR, Sth drive (MT:23) BUSH CINCLIP GEAR, Sth drive (NT:25) eUSH WASHER GEARING, RH GEARING, RH ¢ RING C RING OIL SEAL CAP, counter sheft HOLDER, bearing SCREW BEARING, LH PIN ORIVESHAFT GEAR, Ast oriven (MT: 44) 1) RH 1) LH driven (NT:33) geSgTE CIRCLIP EM, 3rd driven (NT:33) BUSH WASHER, LH WASHER EAR, 4th driven “NT:30) EAA, ath driven (61:30) ar PRP PUN Re Re Re eR RR ee eee Nee model A model S/T model A/S. acdel 1 madel R/S model 7FIG.22 ( D- 6) TRORMISSTION wr MEFNO. PART MO. DESCATPTION RERAIKS, » 2a95L-17E02 GEAR, Sth driven (WT:29) 1 bal 24361-17620 (GEAR, 6th driven (NT:28) 1 BS 09203-20080 GEARING, FH a » 98221-07209 PIN (1:20) 1 ” 09262-28075 GEARING, LH a Ps 09990-70001 C RING 1 ” 09283-36008 OIL SEAL (36x 7006) 1 Lo 24751-17600 PLATE 1 al 01500-06123 SCREW a a2 27310-21£00 ‘SPROCKET, engine (NT:14) 1 4) 08211-25402 WASHER 1 “~ 09180-25098 SPACER (25036x17.7) 1 “ 09159-20008 NUT 1 ” 27600-21£00-108 CHAIN, drive (LOBLE) FX 1 REGOORT EDFIC.23 ( 0+ 9) GEAR SHIFTING FM. PART NO. 1 23211-17600 2 25231-17600 3 23411-26001 a 23411-27900 3 23910-17601 6 00221-00089 7 23312-12000 e 79322-33000 , 09160-07016 10 25323-34201 a 25328-34201 12 09261-05003 b 09440-04003 rt) 25331-26000 us 02112-06309 16 25341-17F00 v 02122-06303 18 O09 1Leu-06202 a 08316-10063 20 09262-25006 i 09160-23059 2 25350-26001 3-1 22335-26010 23-2 25355-26021 boy ¥5336-12000 a 0211-06141 Py 7592 7.2000 - 25510-176'0 Mel 09444-20002 2 O94h4-20003 np 73671-01000 » (09203-14006 n 08211-14221 32 9160-14016 x” 09263-14027 x (08531-31146 RFGOORT ES FORK, quar shifting No.1 FORK, geer shifting No.) SHAFT, fork (L110) SHAFT, fork (L:178) CAM, gear shifting .PIN PIM, shift cam driven gear SHIFTER, com ROLLER Pama, No.1 PM, No.2 PIN ‘SPRING LIFTER, pawl ‘SOREN QUIDE, com SCREW SPACER not BEARING (25x67x8) WASHER (25x32x)) ‘STOPPER, con ‘SPRING ‘SPRING SUPPORT, stopper WASHER PLATE, stopper SHAFT, gear shift ing ‘SPRING ‘SPRING STOPPER, are OlL SEAL WASHER, FH WASHER, LH BEAMING (14x20012) CIRCLIP an Meh. PART wo. __pesungprygy 0 2 1 1 1 1 2 1 1 1 1 1 2 7 1 1 1 1 « i 1 1 L 1 1 1 1 L L 1 1 i L L 1 1 z marl R/S model 1 modal R/S model TFIG. 23 18.23 (0-10) GEAR SHIFTING oO. DESCRIPTION 23320-19002 WM, gear shift Link 23323-21600 ROD, gear shift iimk (L:165) 23525-21610 ROO, geer shift Link (1.:165) 9140-06011 wT (00310-00067 UT 01300-06257 BOLT 23600-1700) LEVER ASSY, gear shifting 23652-16500 PUBBER 23326-47000 »COVER, dust 09160-14052 WASER, shift lever ,R 09160-18022 WASHER ( 10x26x1) 37720-48800 BODY, gear shifting switct, 09200-35006 O RING (0:2.4,10:55.3) 02112-7516) SCREW 09209-03011 CONTACT (09440-08010 ‘SPRING ‘29608-06002 CUP (L550) 9408-06429 GNP (L245) (09604-06427 CUP (1:50) 09808-06426. CUM (L:95) CUA (L380)FIG. 24 FIG.20 ( E- 2) START Ins MOTOR REFNO. PART NO. DESCRIPTION 31100-6€00 MOTOR, stexting 31311-19002 AA TURE, 31130-19810 TERMINAL SET, brush 31143-49080 «0 RING 31132-46£00 BRUSH HOLDER SET 31195-91300 SPRING, brush 31150-86600 «BRACKET ASSY, front 31136 46£00 +0 RING 31156-48800 «0 RING 31170-1981e «WASHER SET 31264-31300 «0 RING 31280-19810 «BOLT ASST 31143-49000 +0 RING 07120-06253 BOLT 09128-0u028 SCREW 00361-33068 NUT 33810-21F 00 WIRE, starter motor 31801-48610 -CAP, startez motorFIG.25 FIG.25 ( E- 3) ALTE WATOR (model R) MERC PART Wo Al 31900-17802 1-2 31400-17820 2 31380 -L7E00 , 31612-06800 4 ‘31613-96800 > 31585-85251 6 31586-L7£00 La JL7LO-L7E02 7-2 SL710-1 20 8 31613-87610 9 31612-88800 10 31613-<7A10 ray 31611-17600 2 31587-85250 wb 31671-27000 le 32300-27000 1S) 31636-80800 16 687-1 7800 v 31480-17600 le 02112-0806) w 31668-27000 2 3614-1 7E00 aL 08310-00053 2 31780-48800 2 02112-05085 a 08321-21055 oO 08322-21055 ro 31156-17100 a 07120-0853 za 22730-21600 2 22734-21600 w 21231-1780 ae (08211-12243 bd 09159-12010 en ALTERNA ‘OR ASSY ALTERNAT.R ASSY -FRAME, d-ive end « «BEARING «COVER, bering « RETAINER, eeTing » SOREW, beer ng retain ROTOR ASsY ROTOR 4357 -COVER (1) BEARING COVER (2) -FROWE, ont + STUD BOLT -WOLDER, rectifier REGULATOR HOLDER, brush: COVER, rectifier LILEAD WIRE. ‘SOREW «SOREW (5017) COVER NUT -O1L SEAL SET -SOREW LOCK WASHER WASHER 0 RING our GEAR, genecator driven (NT:30) HOUSING, dam-er Hi Rafer to F1G.25A(E-5) for model S/i RFGOORT £3 Mee eRe Re er Re ee ee ee eee ee ee ee eee DESCRIP, TOK. es ~€..No.N708-108342 E.Wo.N708- 108343- ~E.No.N708-108342 £.No.N708-LOS}43— birFIG.25 ( E- &) ALTERNATOR (accel A) PART NO. DESCRIPTION 22732-21600 SHAFT, generator drive 09262-25110 BEARING 08331-31256 CIRCLIP 19390-5200): C RING Refer to FIG. 25A(E-5) fur model S/TFIG.23 A FIG.25A( E- 5) ALTERNATOR (model S/T) REFNO. PART NOL 1 31400-17630 2 31580-17600 3 1612-06800 ‘ 31613-48800 5 3ise5-a5251 ‘ 31586-17600 7 J7LO-17E30 ‘ 30419-42810 ? Jisiz-eee00 10 31613-27010 iW N611-L7E00 12 31587-85250 ay 44621-27000 la 32800-27000 1s 31636-88800 | 6 31687-17200 | wv 31480-17E00 ' is 02112-04063 | y 31688-27000 | » 31614-17800 a 00310-00033 2 31780-27450 2 02112-03005 ™ 08321-01033 2 08322-01099 6 31136-17600 a 07120-0863 ~ 22790-2100 2 22734-21£00 » 21231-17610 » 06211-17283 ” 09199-12010 RFSOORT ES ary DESCRIPTION ALTERNATOR ASSY FRAME, drive end - BEARING « «COVER, bearing «Rt MINER, bearing . SCREW, bear'ng retainer «ROTOR ASSY JCWER (1) BES fNG .COYER (2) «FRA, ond «STU BOLT -HOLDER, rectifier «REGULATOR sHOLDER, brush AVR, rectifier LEAD SIRE SOREN »SOREW (5x17) LOOK WASHER 0 RING gout GEAR, generator driven (NT:30) HOUSING, damper OMPER WASHER wT 6 haan RONTeR Chiao 2-48 tint iad maven” aves Re OP RP eRe ee ERRNO eeeFIG. 254 7 FIG.23A( E~ 6) ALTERNATOR (medel S/T) MO. PART » 22792-e6E00 Be 72736-8600: Bd 22780-e6E00: x 9262-25116 nu 09390-52003 RFGOORT €3 10%" SHAFT, generator drive HUB, generator drive COUPLING, generetor BEARING, generator drive C RING an eee eea oI FIG.26 asl eo 1-2 1-3 1-4 vrun Tat 2 FIS.28 ( E- 7) SQL ENERATOR 32900-21£40 32900-21EA0 32900-21£ 70 37900-21680 32980-40001 33110-17E00 33120-17E20 (08221-00089 07130-08303 07142-0510) O22 12-0513 RFGOORT £3 (Qn TER Assy TONITER ASSY TONITER ASSY TONITER ASSY CUSHION ‘SIGNAL GENERATUR ASSY ROTOR, signel PIN our Sew ‘SCREW ery 2 Ls a, a RRR ee ee ee ee model ® endel S/T CALIFUANIA ONLY, modei Kt CALIFORNIA ONLY model S/T model A/S model TFIG. 27 TTT eT ay raarieaear FIG.27 ( E- 6) GATTERY MEN. PAT 1 2 33610-10000 33651-37000 3331-37000 33820-21600 33624-99010 39860-17600 33060-06E00 33690-17600 BATTERY (177, 10AH) YTX9-O5 CUSHION ‘CUSHION (LEAD WIRE (+) .GW, battery plus ‘LEAD WIRE (=) LEAD WIRE (=) PLATE, battery ceution cut as required profile (0n113) cut as required profile (30m15)1G.28 ior Wasa Covia.......- Fae Kui ou on = PART NO. DESCRIPTION RES, 31800-71610 FELAY, starting motor L 2 31061-21610 COVER a 3 09801-30101 FUSE (350A) 2 a 09120-06015 out a 5 33410-21600 COIL, ignition No.1 1 ‘ 33420-21600 COIL, ignition No.2 L ? 09100-06208 ‘SPACER z a 1300-0620) (OLT, ignition coll No.1 2 ’ 09100-06129 WAT, Ignition coil No.2 2 10 39310-17600 CP, speck plug & weir 100 33510-17610 CW, spark plug 4 model S 138 39510-17811 Cr, ark plug 4 model T u 33341-29000 SEAL, plug 4 wa 33542-34800 SEAL, aightension cord a Mb 39343-17601 CORR a lee] 0604 —O6ee CLAMP, high tension cord 1 aodel la-2 (09004-0641 CLM, high censlon cord 1 model S/T RFGOORT £3 oa ae a re ee al FIG.20 ( E- 9) ELECTRICALAGLNO._ PART NO. DESCA=PTTON menwancs 1 34120-21£20 ‘SPEEDOMETER (Mile/Kilo) 1 2 24121-40010 BOK, meer gear 1 3 34132-17000 GASKET 1 a 02312-7610) soww 2 3 34210-71610 TACHORE TER a ‘ 191-218 10 ONGER 2 Tel 34163-14900 SOREW (4x14) 1 model A 12 34164-12800 ‘SCREW (aula) 1 model S/T 6-1 34183-21600 SCREW (4x20) > wodel A 8-2 SYLO-71E0L—SOREW (40) > model s/t 9-1 249-1710 SCREW (3n10) > moc 9-2 4147-19000 SORE (3x10) > model 5/1 19 M>43-08000 SCREW (2122) > lel 34020-21610 WETER, temp 1 wodel & U-z WATTLE METER, tom 1 moat s/t 12 24191-21820 OPER 1 vb 34190-21610 HOOD, meter a Cy 34124-21E 10 oe 1 15-1 34791-13400 SCREW 1 model R U4 0>139-0200) ‘SOREW 1 model S/T ty 36M, 71820 WCX ASSY, pilot 1 Vel 6 Ye-21b CCAD ASSY, oilot bulb 1 eodel & 7-2 36394-21811 CORD ASSY, pilot bulb 1 odel $/T » 09471-12082 ULB (12, 3.401) 5 v 34170-21610 CORD ASSY 1 20 09471-12100 GLB (12¥,1.71) 2 a 09471-12108 GAB (12¥,1.m) 3 22 34950-21622 QAAGKET, meter 1 a OL89-216 10 CUSHION 6 m1 30727-41410 WSER 6 model RK m2 09160-08017 WASHER 6 model S/T 3 09310-00047 wT 6 a“ 09320-08088 GReET 3 2 09180-06044 SPACER 3 FIS.29 ( E-10) SPREDUETER RFGOORI £3VOR FOP wd Rune LT Te et FIG.29 ( C-1i) SPEEDO ign 9192-06027 34710-47041 34938-21600 01530-06123 34938-21611 34938-21620 QUICE, meter No. eo GUIDE, meter No.2 ICE, meter Ho.2 2 er pi ine os woite® CV tebe te Taki ime WONBAL sss unt or]a) FIG.30 oa 1 ‘ 4 ‘ 2 6-1 6-2 ? 8 = ‘ ° cr ~ wy i i z boty ~ FIG.3O ( E-12) reADLae __ PART NO. 33100-21200-999 HEAD ASSY ‘39173-00800 09471-12060 09320-07014 09269-05018 02142-05163 ‘02112-05163 35950-1400 33936-21£00 (08310-0005) RFGOORT E} -COVER, socket BULB (12¥,60/ 5501) CUSHION WASHER SonEw SCREW REFLECTOR, front side GRACE T wut ety ee oo AAS model R/S model 1FIG.3) RENO. 1-k 1-7 2 wer eneena au wa FS rT) 1s ie Vel 2 16-1 18-2 » FIG.SN ( &=13) TURNS CAL Lane PART NO. 33601-29019 33601-2990 33617-17020 3913-27000 35423-27800 35725-A0511 39627-27002 O9a71-12085 35678-27001 083 16-LOLOd 35603-2130 33652-1°C20 39613--27M00 33623-27000 33725-80911 33627-27012 ‘09471-12005 08316-10103 (08310-0010) 09160-10094 09260-10501 33695-17000 38610-45001 AFGOORT E} CRIPTION LUM ASSY, front turnsignal LP ASSY, front turnsignal LENS GASKET TAPPING SCREW - TAPPING SCREW -GASKET «BULB (12¥,21m) erent nut LAMP ASST, reer tumsignal LENS BASKET

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