FOREWORD “This manual contains an introductory description (on the SUZUKI FUS0SC and procedures for its spection/service and overhaul ofits main ‘components Other information considered as. generally known is not included. Read the GENERAL INFORMATION section to {amiarize yourself with the motorcycle and its maintenance, Use this section as well as othor sections a3 a guide for proper Inspection and service, “This manual will help you know the motoroycle btter so that you can assure your customers of fast and reliable service fo) (of UE lS ¢ ‘GENERAL INFORMATION E 1 | PERIODIC MAINTENANCE ra ENGINE Em FUEL AND LUBRICATION oi [ * This manual has been prepared on the basis of the latest specifications at the ‘ime of publication. If modifications have been made since then, differenoas may exist between the content of this manual and the actual motoreyele, + tlustratone in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual motorcycle exactly in detail This manual jg written for persons who have enough knowledge, skis and tools, including special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motoreyele dealer to help you, oom Inexperienced mechanics or mechanics without the proper tools and equipment may rot be able to properly perform the service Cdeseribed in this manual. Improper repait ray result in Injury to the mechanic and ‘may render the motorcycle unsafe for the fider and passenger. j= s/t — ELECTRICAL SYSTEM tm SERVICING INFORMATION 7 |HOW TO USE THIS MANUAL SYMBOL TO LOCATE WHAT YOU ARE Listed in the table below are the symbols Indicating instructions and other information LOOKING FOR : necessary for servicing and meaning associated with them respectively. 1. The tot of tis manual is cd into sections 2. As the te of these sections ar ised on the previous page as GROUP INDEX, 6 You are looking for belong, 3, Holding the manuel 9 shown atthe right wl alow you to ct the section where what svMBoL, DEFINITION SYMBOL DEFINITION ind tho frst page ofthe section easily 4. On the fest page of each section its contents aro late, Find the tem and page you need Torque convalreaured Data beside tinclestes specified toraue. ‘Apply THREAD LOGK "1342" 92000-32050, ‘Appy ol Use engine ol ures otherwise specited [Apply THREAD LOCK 1380" COMPONENT PARTS AND WORK TO BE DONE. ce Under te rame ofeach syste or unt ts exslded vow ie provide wth wor ttn acd other AY SURIKT SUPER GREASE e Apply oF use brake tid ‘servos infomation such as the tightening torque, Lubricating polnts and locking agent points fn Example : Front wheel Seeonca eel ‘Measure in vottage range, [Apply SUZUKI WOLY PASTE 98000-25140 Massie i resistance range [Apply SUZUKI BOND =7218' Measure in current range eee 4a AA Ae e/a \c 00-3110 | ' “Apaly SUZUKi BOND “T2078 Use special too | ‘90000-31140 | [ARB THREAD LOK SUPER Pear | "900! 9000-s9044-106 9000-52030 | | |CONTENTS WARNING/CAUTION/NOTE, GENERAL PRECAUTIONS... SUZUKI FUI50 SC. SERIAL NUMBER LOCATION... FUEL AND OIL RECOMMENDATIONS... FUEL ENGINE OIL, BRAKE FLUID. FRONT FORK OlL BREAK-IN PROCEDURES... ‘SPECIFICATIONS.1-4 GENERAL IMFORMATION WARNING/CAUTION/NOTE Please road this manual and follow its instructions carefully. To empheslze special formation the symbol and the words WARNING, CAUTION and NOTE ha messages highlighted by thes signal words. Indoates a poten ACAUTION Indicates @ potential hazard that could resutt in motoreyele damage. special meanings. Pay spacial attention to the 3! hazard that could result in death or injury. nore Indeates special information to moke maintenance ser or Instructions clearer. Please not, howsver, thatthe warnings and cautions containes in this manual cannot possibly cover all Dotentil hazards relating to the sericing, oF lack of servicing, of the matoreyle. In adtion to the WARNINGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles, {you are unsure about how to perform a particular service operation, ask a more experienced machaniz for advice GENERAL PRECAUTIONS * Proper service and repair procedures are important for the safety of the service mechanio and ‘Wen 2 or more persons work together, pay attention to the safety of each other. ‘wen it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors When working with toxic or flammable materials, make sure that the area you work in te well-ventilated and that you follow all of the materlal manufactur Novor uso gasoline as a cleaning solvent. To avoid getting burned, do not touch the engine, engine oll or exhaust system during or for a while after engine operation [After servicing fuel, oll exhaust or brake systems, check: system for leaks. 's intructions ines and fittings related to the [GENERAL IMFORMATION 1-2 * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent When removing parts that aro to be reused, keep them arranged in an orderly manner so that ‘they may be reinstalled in the proper order and orientation. Bo cure to use special tools when instructed. ‘Moke oure that all parts used in reassembly aro clean, and algo Wbrieated when specified ‘When use of a certain type of lubricant, bond, oF sealant is specified, be sure to use the specified ype. When removing the battory, disconnect the negative cable first and then the positive cable, When reconnecting the battery, connect the positive eable fist and then the negative cable, nd replace the terminal cover on the positive terminal Whon performing service to electrical parts, if the service procedures not require use of battery power, dleconnect the negative cable of the battery. Tighten eylinder head and case bolts and nut, beginning with larger ciametor and ending with smaller diameter, from inside to outside diagonally, to the specified tightening torque. ‘Whenever you remove oll seals, gaskets, packing, O-rings, locking washers, sel-locking nuts cotter pins, ctclpe, and certain other parts as specified, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the ‘mating surfaces. [Novor rouse a eirelip. When instaling a now citcip, take core not to expand the end gap larger than required to slip the circlip over the shaft. After installing a elrlip, avays ensure that itis Ccomplotely seated in its groove and securely fitted. Use a torque wrench to tighten fasteners to the torque values when specified, Wipe off grease cof ol i thread is emeared with them. After reassembly, check parts for tightness and operation ‘To protect environment. do not unlawtully depose of used motor ell and other fide: batteries, and tires, To protect Earth's natural resources, propery dispose of used motorcycles ‘and parts.1-9 GENERAL IMFORMATION SUZUKI FU150SC RIGHT SIDE LEFT SIDE * Diference botwesn llustations and actual motorycies depends nthe markets SERIAL NUMBER LOCATION ‘The frame serial number or V.LN. (Vehicle Identification Number) (2) is stamped on the right side of the, steering head pipe. The engine serialnumber (2) Is located on the lower ide of the crankcase. These ubers are required especialy for registering the machine end ordering spare parts ct FUEL AND OIL RECOMMENDATIONS FUEL. Gasoline used should be graded 91-95 octane (Research Mathod) or higher. An unleaded gasotine type ks recommended GENERAL IMFORMATION 1-4 ENGINE OIL Be cue thatthe engine of you use comes under ‘AP clastcaton of SF or 9G and thats vicosty ‘ating is SAE 10W/40. I and SAE 1OW/A0 motor ‘lis rot avaiable, select and slemate according to the right chart. = ey ep ee ee BRAKE FLUID B svccitation and classiteaton oT 4 CNS ‘Since the brake system of thie motoreyole le filed with a gleo-based brake fuld by the ‘manufacturer, donot use or mix diferent types of fluid such as slicone-based and petroleum-based ‘luid for roiling the system, otherwise serious damage will result Do not use any brake Muid 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 ol # 10. BREAK-IN PROCEDURES During manufacture only the best possible materials are used and all machined pats ar fished to avery high standard out i tl necessary to alow the moving pats to "BREAK-IN" before subjecting the engine to maximum strasesa. The future performance and rlalty of the engine depends on the care and restraint exercises ducing ts eaty if. The general es are 2s follows. ‘+ Koop to this breakin thatle positon, Initia 200 km: Less than 1/2 throttle Up to 1,600 km: Less than 9/4 throttle + Upon reacting an odometer reacng of 7600 km you can subject the motorcycle to ful thot operation foe short porods of tne1.5 GENERAL IMFORMATION (GENERAL INFORMATION 1-6 ‘SPECIFICATIONS cHassis Front suspension. “elescopi, col pring, ot damped 1940 mm Rear suspension ‘Swingarm type, eo spring, of Semped j 6520 mm swesing angle. 45" (ight & eh) 961mm C8 nnn 2s 1280 mm 96 mm 704 mm 20m ; 140 mm Dio brake 5g Die brake Front tke 926. 7090-17 568 Fear to za _ 00-17 448 Fourstroke, DOHG, aicooled Frot frk stoke. 80 mm z Fear wheel revel mn 100 a i 620 mm | 488 mm ELECTRICAL | 1473 om? lon type. ctoicfniton (001) 02:4 Igetion tring. 5° BDC. st 1500 min MIKUNI 8s 26-167 Spark plus NGK GABE or DENSO U24eSR-N Paper ype 12.25 An 10 HR Kick stator AC. Generator Wet sump 10a 12V sosesie/taw ‘2v t0W Wot mutpate type 2v 196 ‘seed constant mech LED (AMBER) ‘down, 1p LED (GREEN) i a vemonnane 8500 (70/20) LED (AMBER) Fal ection ro wenn 071 asia) High beam lncator gh LED (BLUE) 2780 (ag Tarn signal indeator Hight. LED (AMBER) ‘785 256) 168 2879) ‘CAPACITIES 1088 (2921) FB £8 ne 49L o919 x23) Engine ol ol cheng +000 mi 800 (2025) ‘wan iter change — e100 md Dive chain. 1100 ODH280S, 122 tks overaul. 1.200 i Front fo inn : vos 1095 mh Noto These specication are subject to change without notice. fm| een LA CONTENTS: 4 PERIODIC MAINTENANCE SCHEDULE. povwomene = 1 PERIODIC MAINTENANCE CHART. at LUBRICATION POINTS. eB MAINTENANCE AND TUNE-UP PROCEDURES... “23 BATTERY... a 23 | EXHAUST PIPE BOLTS ve 3 AIR CLEANER, Oe wes TAPPET CLEARANCE es i SPARK PLUG ee 0 | ENGINE OIL AND OIL FILTER Tait | FUEL LINE 22 | cuUTCH. : coe 212 | CARBURETOR. en | THROTTLE CABLE PLAY. a1 | PAR (AIR SUPPLY) SYSTEM een AS | DRIVE CHAIN. 7 es BRAKE - ass | Tre — | STEERING, — see 248 | FRONT FORK. ee i REAR SUSPENSION. ss sonmnnnnen BAD | CHASSIS BOLTS AND NUTS. Tae | OIL. PRESSURE CHECK. 7 ~ 2212-1 PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE ‘The chart below Its the recommended intervals for all the required parocie servoe work necesssry to keep the motorcycle operating at peak performance and econcmy. Mlleages are expressed in emis of Ilemters and tine for your convenience, nore : More hequent servicing may be performed on motorcyciea that are used under severe conltions PERIODIC MAINTENANCE CHART = Interval = [kip | vooo" | soon [aonb 32600] anoo | sateo'] zane foe IMenithe 3. Battery Exhaust pipe bats Ar loaner Valve clearance Spark pg T Engine of Ja |» |~ fo fa Lo Ble 2 |- lola g 2 Engine ol ter Fuel hose : ‘ute : Hi er ae Drive chain of ee -FEEF Baa id a Tie ‘Steering (vind head at ‘Suspension (Chassis bots and nate PAIR (ar supply) Syste NOTE: | Inspection and adjust, clean, Lubricate or replace as necessary ©: Clean Fr: Replace T: Tighten PERIODIC MAINTENANCE 2.2 LUBRICATION POINTS Proper lubrication is impertant fer smooth operation and long Ifo ofeach working part of the motorcyte, Major Lbrcstion points are indicated below. ABH : crease Bit Bp ne te FRE rat ever bolder / EBA Yio stair ovr ia ABA ore pd hot FB SGo-stand pivot Drive chain ‘ang spring hook A Genter stand pivot * sd spring hook NOTE: * Before lubricating each part, clean off any rusty spots and wipe off any grease, ol. dirt or rime. * Lubricate exposed parts which are subject fo rust, with a rust preventative spray whenever the motorcycle has been operated under wet ér rainy coneition.2-9 PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES: “his section describes the servicing procedures foreach em ofthe Parodie Maintenance requicements, BATTERY Tnepectinitaly at 1,000 km (¥ month) and ] Every 4000 km (4 months) thereattor. ‘The battery must be check the veltags 1+ Open the seat ‘Check the battery votage Measure the voltage is belween & ‘teminal ane ©teminal of battery 28 shown, Ifthe voltage checked fs below 124 v the battery need recharing When remave the battery diconnect the negative cable (Gat and ton the poste cable (3) «hen instal the battery connect the postive cable fst ‘and then the negative cable -) EXHAUST PIPE BOLTS. “Tigten intially at 1,000 ken (1 month) and Inspect every 4,000 km (A months) thereafter. «Tighten the exhaust pipe bats and mfr meuniig bot “nd ri to the specie orque [F) exnaust pipe bot: 14 em (1.1 gm) ‘Muter mounting Blt and nt : 26 Nm (28k) PERIODIC MAINTENANCE ‘AIR CLEANER, 1¥ te ar cleaner is clogged with dust inake resistance will be iereased with a sultant decrease in output anc an incre in fuol consumption. Check ang clean the element in the following mary + Remove the frame cover (Refer to pace 5-2) + lomove the alr cleaner alemant by removing the sere 1 Toke off the ar oloaner clrmont 7 ‘ ae «+ Carefuly use air hose to blow the dust from the cleaner 7 AcavrOn| | ‘Always use at presaire on the ide ofthe steal shoct | {i aiving under dusty condition, clean the ar cleaner ‘element more frequently, The surest way to accelerate engine wear Is to use the engine without the element orto lie @ rupted element Make sur that the ar coaner is in good condition at al mes. fe ofthe engine depends largely on this component!2:5 PERIODIC MAINTENANCE. ‘TAPPET CLEARANCE Inspect every 12,000 ka. | ‘Remove the cente eg shld and right and lft og shies. (Rotor to page 5:2) ‘Disconnect the spark plug cap and remove the sper pug 1 Rarove the oyinder head cover, ‘The tappot clearance specification i cert for intake and exhaust valves “Teppst clearance adjustment must be checked nd acusted, 1) atthe tie of parole napacton 2) when the valve mechanism i serviced, enc 3} when the camshats are tured by rernovng them for sonicing Teppet clearance (when cold): IN, : 010-020 mm Ex 020-00 mm nore : “Tho piston must be at Top Dead Center (TDC) an the comeression stroke In order to check the tappet clearance or to adjust tappet ciearance "The clearance specication Is for COLD stat, + Remove te paneer cover cap and ae tng repcton is ® ‘+ Ftate the generator rotor witn box wrench to set the piston at (TDO) of the compression sroke. Rotate the rotor unt ‘tho “T" ne onthe rotors algned withthe center of hole on ‘he generator cover) 1 Use a thickngss gauge between the tappet and the cart the clarence Is out of specication, bring It Into the speciied range 9900-20808 : Thickness gauge PERIODIC MAINTENANCE 2.6PERIODIC MAINTENANCE 2-6 su og pom ogo ons ws | sw oes se we oem eee | | wu ree sewn vo, ez are ore naw, wz] srz fare | we moo event Wee re [ove | soe | 02 usa we raid ye uun9® ope eCUNEEP LPH wea} are} ore] soe fave | a7 a wn saat anced [ez sre ore soe |ooe | ser [ow 700 81 BNR, sou ode SON 1 ez sre ore] soa one [ser [oer [5 ‘Lang siu.asn OLMmON [Gzg) re| ore) woe / x2) opr [ast [oar [Orr wee} sre] ore] sve | ove] a ont [set [one [SZ [eee [sre Ore | soe] oz | sor fom [sor one fers [art Bez sre | ore] we | Ove] we [ oer [ew OF [SeE ea sare] sear se | arse act arom ez re] are ae | ewe oo a |store zoe |r [ator [cv ox fac ore [ast [ost] —— arora sree sae] sara S| parrots | asst sPa| —ereara za ara [are are [ose || asv av eor [at [art at [ant ar[ort vr [er] seo eee fare ae ove [eer Swarr f ac sf wr at |r ve [ar =e1| —— oar [ees area oes wr fs arta i] arora ions NERS er aoa Tea sat] apa] or] soc |r [or] a eH] |S woe ove sree az suf stor |r ors |e or er | a oO [ tu aonTO oze| sos | xe ore| ses | ors | ssl ot| sexes} rsa | ou ya ora| sears | suo om ee [: rai cous ow van ze sz sx| oe ss] os |] on] sc] ax] ss] ots or] on |e] oe) ex] em| 8 (0zgs0-00821)'ON 13S WIHS Laddv. (0cxx-00050-26821)'ON WIHS Laddv. (INTAKE SIDE) ‘The claranoe is acjusted by replacing the exting tappet shim ‘TAPPET CLEARANCE ADJUSTMENT by a thicker or thinner shim. 2:7 PERIODIC MAINTENANCE (@¥VLNI) F1aVL NOLLOSTSS WIHS LaddVL ot a of £288 5 e982 ret tna 1 Ei i i 3 Ha i é 5 guest § y) Guan GE iL THY eit ae en i? Hila Pade HH F Boapiee 2 29) #86220 3 Pi PGHGE Eh, (EPH E in upan ETE IB het bin taay | Gel Dyas 4 se pence rm ge2ik HOHE: chad ai ue10 PERIODIC MAINTENANCE 2.9 PERIODIC MAINTENANCE Inspect every 4000 km (4 months). ‘SPARK PLUG. (EXHAUST SIDE) eegeg 2 33 2 iS giaga teil i ae | lez tut gigit aie og [jae | ge Ho H Suir Mas | (gfe vie] 8 op lg gate tee 28g B| F gee gigipe Gite oa 2 VFS Uy | ae th lead PHL HE pt Lebel) Gap Eg 2 283 = € Boe aS : bepriadiges sPialol; ik seiko liad 3 erettpiedd Ege ae el8 a3 ge ais g sf S32 Z| . ge : Heil PP | ip iE lilt 2838 e223 F gf283 3 beebheaiaydgie s/f 4 HE H 2 fil HUNT bret gba lile FP | 2) ag Slee “| Pea be Gbes see 7? EG ia eres ar Sarees a seee a ae ate co EE a azefata fae eer ea od eS ad asa pose see sonal eo eS Tnonoeioe profs eee ie zal ectuo ns eta oof es a a xa Se — elena adesaa eS sre rz se wor oat [sero rt avefa foetus cee Se Ea Game ae seo] so on me ooo aa sen feof f afar Hartree ao ozz| 912 | ore| soz] a0z | sev) ost | set] cet ost} ssi} oft] svt| ort} set} ort | se | oe | (sue o- iBadvL ean ozs] suelo | |x sr] os | ots |u| | os] sr] ons |v on} se os |e ce] OM on (ozego-00821)'ON LS WIHS LaddVL (0xx-00090-Z6821)'ON WIHS Laddvi. (snvHxa) 31av1 NOWLOTTAS WIHS 13ddVL2-11 PERIODIC MAINTENANCE ENGINE OIL AND OIL FILTER (ENGINE O11) place initially at 1.000 km (1. month) and Every 4000 km (4 monthe) thereafter (ou FILTER) Replace initially at 4,000 krm (1 month) and Every 8,000 km (8 months) thereafter. ‘The engho ol shoul be changad whi th engine is hot Oi (er repiacemert atthe above Inara should be done togater wih engin of change « Koop tho metoryee upg wth canter san ¢ Pace an ol pan unde the engine, + Fmove the engine of ran oleg @ and o fier cap @) io aran engine o «Remove the ote exp © by removing the nt and bots ‘= Remove the oll filter (4) and inatall the new one. + Roplace th tse cap @) and tghton the nut and bots secre, note: Bofors istatng the new of iter and iar cp, check to bo sure thatthe epring(S) anc new O-rings). (are tated comect <*Taten the ol dan lag ®t the specie trae [Eon rain pug #18 Nem (1.8 kgm) 4 Sippty a good qually mut-grade motr ol Tien te ol er cap @) 4 Stat up te engine an aiow fo rn or save! mints ating speed «Tun off he engine and wait about one inte + Check the ot evel with te ol avel incom tte ove is below the "F* mark, ed oll uni evel reaches the °F° mark Ol vssosty and clasiation : SAE 10N/GD with SF of S@ NECESSARY AMOUNT OF ENGINE Ott it change 4.000 mi Oi iter change 1,100 mi Overhaul 11.200 mi FUEL HOSE, Inspect every 4,000 km (4 month), Replace overy 4 years. CLUTCH _ Tnepect italy at 71000 kev (7 month) and Every 4000 km (4 months). «Loosen the lack nut Dane turn the astray in ‘Loosen the look nut(@) and acust the eth lover play @) wi the asusor @ to the sects play. Clutch over play @) : 1048 mm ‘sTiohtan the lock nuts ©, @ CARBURETOR Inspect intialy at 1,000 kr (T month) and ‘every 4,000 km (4 months) thereafter. IDLE RPM (Idling adjustment) + Adjust tho toto cabo pay. (Refer to page 2-18) + Warm up the engine Nore: ‘Make this adjustment when the engine Is hot + Connect an electric tachometer. «Start up the engine and sat ts speed at any where between 11300 and 1.500 r/mi by turning throttle stop screw. Engine ele speed : 1,400 100 min EB) 02200-22000 : Tachometer PERIODIC MAINTENANCE2:13 PERIODIC MAINTENANCE THROTTLE CABLE PLAY ‘Trrtiocablo play @®) shouid be 2-4 mn 8s measured at throte rp when tring te tte gre ight he play (A) Inthe trot cable i Incarect acu nthe flowing way: ‘+ Looson th loc nut and tun the ester (2in or out nt the spect pay le obtined ‘Tighton tho lock nut @ whe hoking the aduster @. Tarot cable play (A): 2-4 mm ‘After the adjustment is completed, check What handlebar movement does not raise the engine idle’ pied and thatthe throtle grip roturs smoothly and automaticaly PAIR (AIR SUPPLY) SYSTEM Inspect initially at 12,000 km + Femove the canter cover tame. 4 Remove the font cover ame let and ight ‘Inspect the vacuum hose and Air hose) for camage ‘Inspect the PAIR CONTROL VALVE for demage + Inspect the PAIR REEDVALVE for he carbon depost the ‘eon cepott i found inthe reed vate, replace the PAR, contro vavewth& naw one, + Inspect that alow through the PAIR conto vate If ar des not fw out, epics the PAR vae with ane ne. DRIVE CHAIN Tnspet iiially at 7000 km (T month) and 1 Every 4000 km (4 months) thereafter. Clean and lubricate every 1,000 km, Visually inepect the drive chain forthe below listed poseibie rmalcondtons ! * Loose pins Damaged rors + usted fnks + Tuoted or seized tks + Excessive weer any defects are found, the dive chain must b ACAUTION ‘The standard drive chain le DIDO DID#2S0S. SUZUKI recommends that this standard drive chain should be for the replacement. CHECKING 4 Loosen te ate nt . ‘fense the ave chin flyby acting chan scjustr ruts) ‘Count aut 2} pins 0p) onto han measure te distance between the two. Ifthe distance excoed following lt. he chin must be rop2cec Dive chain 20-pitch I Note: When replacing te cive chain, rpiace the drive chan an! proces asa et th : 259.0 mn ADJUSTING ‘Loser the aojustr nuts(@) unt the chan has 15:25 mm of ‘ag at the midale between engine and roar sprockets. The ‘mark @) on both chain adjusters must be atthe same foston onthe ecale to ensure thatthe front ar rear whos: se correctly aligned i ‘Tight the ania nut @D after adjusting the dive'chal a tighten the acluster nts @). . Ror axle nut : 64 Nem (54 kg-m) CLEANING AND LUBRICATING ‘Wash the drive chan in clearing solvent and lubrcato it with chain tube or motor ol fhe motoreyle operates under dusty, ‘contlons. frequent rapid acosertion or at sustained high speeds, the dive chain shouldbe cleaned ard ubvicatod ore ofen.2:18 PERIODIC MAINTENANCE BRAKE (BRAKE) Inspect initially at 3,000 km (1 month) and ‘every 4,000 km (4 months) thereafter (BRAKE HOSE AND BRAKE FLUID) Inspect every 4,000 kim (4 months). Replace hoses every 4 years. Replace fuid every 2 yea FRONT BRAKE FLUID LEVEL «+ Keep the motoreycla upright and place the hancebar etait “Cheek the brake id level by observing the lowar iit tne fone the front brake fui reserva. ‘When the level is below the lower im tne, replenish with brako fui that moets tha folowing spsciication. ‘Specification and Classification : DOT 4 Tho brake system of this motorcycle fe filed with a ‘yeol-based brake fluid. Do net use or mix different ‘ype of fd such as sitcone-based or petroleum-based Do not use any broke fluld taken from oll, used or unsealed containers. Never re-use brake fli left over {rom the last servicing oF stored for a long period. ‘rake fui, if i oaks, will Interore with safe running ‘and immediately dlscolor painted surfaces. Check the brake hoses and hose joints for eracke and oll leakage before ring REAR BRAKE FLUID LEVEL ‘+ Keop the metoreycl upright and place the handibar straight + Check the brake fu level by observing the lower tim ne ‘one the front brake uid reser, + Won the level is below the lower limi ne, eepnish wth ‘rake Mui that meets the following specication ‘Specification and Classification : DOT 4 BRAKE PADS ve the brake caliper “The extent of brake pad wear can be checked by observing ‘the grooved it ne (D)on the pad. Whan the wear exceed the grooved limit no. replace the pads with new ones. (Ro fer to page §-10) Acaution otherwise braking per formance will be adversely affected AIR BLEEDING THE BRAKE FLUID CIRCUIT ‘rapped in the fuié cout acts tke @ cushion to absorb & large propoton ofthe pressure developed by the master oy incor ard thus interfeces wit the ful braking performance of the brake caliper. The presence of air is indioated by spanginess” of the brake lever and also by lack of breking force. Consisting the danger to which such trapped alr exposes the machine and rider, it Is essential that, after remounting the brake and resting tho brako system to the rnotmal conftion, the brake fad cout be puged ofan the ‘olwing manner: “Fil up the master cylinder reserwir to the upper end ofthe Inepoetion window. Replace the reser Cap to pr anty of ct ‘Attach @ pipe tothe calperbleeder valve, and inset the fee tnd ofthe pipe into a receptace, 1 Bleed ai rom the ar Bleeder valve, 1 Squeeze snd release the bake lover saver! tines in rapid succession and squeeze the lever ful without relessing it Loosen the bleed valve by turning ita quarter ofa tum so thatthe brake fud runs Into the receptacle; tis wil zeove tha tenelon of the brake lever causing It to touch the hancleber grip, Then, close the vas. pump and squeeze the lever, nc opon the vale, Repeat this process unt the ula flowing Inte the receptace no longer contains abu nore : Reps te brake ful in the reson 36 necessary while Dice the brake system Make sure that there avays soe Tid ible inthe resaroi «Close the biaeder valve, and daconnect the pipe. Fl the rose ity rae ls 0 the “UPPEFT ano he iepection ‘wngon [BAe seeder vane: 80 Nm (08 kam) [A.cauTion| PERIODIC MAINTENANCE 2-162:47 PERIODIC MAINTENANCE PERIODIC MAINTENANCE 218, REAR BRAKE PEDAL HEIGHT . TIRE 4 Losen tho fsk rut Dand tum the adster@ to oat to [neve ery AST omiw rake pedal height ®) 6 mr) below the tp face ofthe TIRE TREAD CONDITION footrest. + Tighten nut ook Operating tha motorcycle’ with excessively. wor. tes crease riding stability and consequently inte a dangerous situation tf ight recommended to replace a te when the Femaining depth of re tread resches tho folowing speciation, “ire troad depth limit (Font and rear): 1.6 mm TIRE PRESSURE oH Wf the tre pressuro fs foo bigh or too low, teeing, will be « averse affected snd tire wear increased. Therefore, maintain the correct tie pressure for good readability or shorter re fe depth gauge wl osu Co inflation eo presse 's as folows. ‘COLD WAATON'|— SOLD ADNG [DUAL RONG ‘ine paessuRE [psi | igem™ | psi_| gent FRONT | 225 | a2 | 225 “ FEAR 250 | 381280: | Beayron j E “Te elandad tre ited on this motoroyee Te 70/80-17 285, {or front and B0/G0-17 44 for rear. The uso of tres other i than those specified may cause instablty. It is highly | recommended! to Ges the epecited tres, | STEERING | [inspect ita at 1.00 kaw CF month) and : Every 8000 km (@ months) thereafter. l Typo bears are equipped onthe staaiag ston Siig | sold be adised proper for smecth ting of hanabare | ae safe reming. Overtgn tering prevents smoot tuning || eftmonandebare and too tose steer wi cas por tabi Check that there Is-no-payin-the tof asso by supporting the machin shal he ort eis ofthe gourd, 1 staght ahen grap the tower fork tubes near te axe and pull forward play is fone, perform steering beaing austen as deserbed page 5.27 of hs mara. ‘wth the ee2.19 PERIODIC MAINTENANCE FRONT FORK ‘every 8000 km (@ onthe) in Inspect the front fore foro leakage, scoring or soratches on the outer surface of the inner tubes. Replace any defective para, if necessary. (Refer to page 5-16) REAR SUSPENSION [Inspect every 6000 kam (@ months). Ipspect the rear shook absorber for ol leakage and damage: Replace any defective parts if necessary. CHASSIS BOLTS AND NUTS ‘Tighten intally at 4,000 ken (7 month) andl Every 4000 km (4 months) theroa necessary to tho specified torque, (eer to page the motoroyela) ‘The nuts and bolts Hsted below are important sally related parts. They must be retghtened when forthe locations ofthe folowing us and bots on eM iam tom [Dream 3 53 @ Storing som head bok rr 85 (@) Hencebar meuring bot 20 2 @ Hendebarmeurtng nt 28 28 © Front fork cap boit 45 45 (@ Font or cap ba zs 23 (@ Fron brake masior onder BE ra 10 © Font oaks how union bl 2 23 (@ Fron orate caper meuning bok 28 26 {9 Front brake air bleeder valve 8 7 @ Pear axio nut 7 54 54 @ Engine mounting nut 66 6s | Erane moun bot a ai @ Front footrest bracket balt 26 26 Front footrest nut 50 50 40. Svingam pot nk o ee | @ Rear chock absorber nut jue | 92 32 L 0 50 50 @ Raw baa paced bok 10 10 PERIODIC MAINTENANCE 2-20,2:21 PERIODIC MAINTENANCE OIL PRESSURE CHECK Check perioizally the ol pressure in the angine to judge roughly the condition of the moving pats COL PRESSURE SPECIFICATION ‘Above 80 KPa (03 kg/em2) : F Below 80 kPe (os tefenay At GOD r/min, OF temp. at 60°C 1 the oll pressure fs lower or higher than the speciation, the following causes may be consdseed. LOW OIL PRESSURE * Clogged ol ter * Oi leakage fiom the of passage way * Damaged 0-ting * Defective oil purnp * Combination of above items HIGH OIL PRESSURE Used an engine of which Is too high vecosty * Giogged ot passage way * Combination of above tems OIL PRESSURE TEST PROCEDURE Check the oil pressure in th following manner. ' Support the motorcycle with the centr stand ‘Remove the bok for Inspect cil preseue test procedure at cover euch side ‘Insta the oll pressure gauge with axeptar in the position shown Inthe figure cc tachometer, + Warm up the engine ae fll: ‘Summor 10 mi. a 2000 rnin Winter 20 min. at 2000 nmi, + Aftr warming up, inersase the engine speed to 3.000 rnin and read the ol pressure gauge o001s-24810 ou pressure sage (09915.72810 : Adaptor (29000-26005 : Tachometer ‘Connect an Al PERIODIC MAINTENANCE 2.22 COMPRESSION PRESSURE CHECK The compression of a cyinder isa good Indicator of ts Intel condition, ‘The decision to change the cylinder with piston set is often basod on the results of compression test Periodle maintenance record kept at your delership should Include compression readings for each ralntenance service. COMPRESSION PRESSURE SPECIFICATION Standara 180 Kalen a COMPRESSION TEST PROCEDURE NOTE * Before testing the engine for compression pressure, make sure thatthe eer had nuts are tightened fo the specified torque values and valves aro propery adjusted. * Have the engine warmed up by taling bore testing * Bo sure that the battory used i in fuly-charged conction, Remove the parts concerned and test the compression pressure inthe folowing manor, + Suppo the motoreycie with the center stand «Remove the spark plug, + Fi the compression gauge lathe plug hole, whl taking care ‘hat the connaction ght + Keep the throte gro in fl-open postion, + Wile cranking the engine a few seconds with the starter. and record the maximum gauge reading as the compression of that oylinder (08015-64510 : Compression gauge (08616-69310 ; AdaptoreS CONTENTS ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE cnn ENGINE REMOVAL AND REINSTALLATION. | ENGINE REMOVAL. ENGINE REINSTALLATION, ENGINE DISASSEMBLY. ENGINE COMPONENTS INSPECTION AND SEAVICE. - CRANKCASE BEARING AND OIL SEAL CYLINDER HEAD, (CAMSHAFT. CYLINDER. Z PISTON AND PISTON PIN. (CRANKSHAFT AND CONROD. CRANK BALANCERSHAFT AND GEAR. | ‘TRANSMISSION, PRIMARY DRIVE GEAR, z CLUTCH. ENGINE REASSEMBLY.9-1 ENGINE ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE ‘The parts ited below can be removed and relnsaled whtout remoting the engine from the fame: Fofer to the page Isted in each section for removal and reinatalaton nations ENGINE LEFT SIDE Engine sprocket Generator cover rotor ‘cam dive chain postion soften Gea ENGINE CENTER Mutter Oarburator (cam ene tension actor Cyeer head cower Camehat finder hea Oytindor Piston ENGINE RIGHT SIDE Outen cover cute Primary deve goar 08 pure ENGINE REMOVAL AND REINSTALLATION ENGINE REMOVAL Bere taking the engine out of he frame, wash the engine wih stam coarer. The procedure of engine revel Ie sequently explained ia te flowing saps 1 Suppor the matoryce with te center stand {+ Romove the of ran plug to dain out engine ob Refer to page 2-1) + Open the seat and eaconnec the battery) wie. Petr to pages 2 and 62) «Remove tho tae covers end lg shies. Ree to page 2) ‘Remove tho tt fotestiar withthe gearshift ever and ‘ight ootestoa + Remove the lower coming + Remove the exhaust pipe bots @) and mutter mounting bate @ + Remove the ol cooler bots @) ENGINE 3-22-3 ENGINE 3 ENGINE 3-6 «Remove the cic release a itn lth cable @. { Dsconnect te canoe breather howe ‘losconect te iehoee @) and vacuum hose @ot PAR (AR SUPPLY) sya + isconect the saver esd wires en park plug can. @: Gereraer ead wre coupe Q Gear position switch lead wire coupler @: Enone ground wre comin ©: pees sensor wie coupe «Remove the carburetor by loosening the carburetor clamp Gasoline is very explosive, Extreme care must be taken, «+ emove the engine sprocket cover 1 Remove tho epeod sensor goar @). 1 Remove the engine sproket bats (8) Nore: When loosening the engine sprocket nut, depress the rear brake peda 1 Femoue tho engine sprocket wh drive chain ‘Remove the engine mounting blts and dismount the engine ENGINE REINSTALLATION Festal the orgie in the reverse order of engine removal, ‘Install the engine mounting bots ard apply THREAD LOCK ‘SUPER "1903" to the thas of toe bol, 1s Tighton tho ott and nuts tothe spect torque 2 90000-92090 : THREAD LOCK SUPER "1900" ‘nut @) + 66 Nem (66 kg-m) DB Erane mounting So): 91 em Ga Kom) + Loveon the roar awe nut ane’ drive chaln saster ruts «When instalng the engine sprocket, face the tapered portion of sprocket damper to the crarkease. ‘Acaurion] “The drive chain joint that eh ip should be attached in the way fend will face opposite to the direction ofENGINE 8-6 «Tighten the engine sprocket to te spect torque [F] Sprocket nut: 10 om (1.0 haem ‘Install the spodsensor on the engine sproket, ‘Tighten the speedsensor dot to specie torgue [¥] seeedsensor bort : 20 Nem (20 kg-m) Nore : Wher tightening the engine sprocket nut, deerese the rear brake peda *Tioten the exhaust pipe bots and mut mounting bot ne nxt to pected torn (FD exaust pipe ott 14 nem (1.1 Kem) Mur belt and nut 26 Nom (26 kom) [AcauTion] ‘Check the wir, cable and hove routing, (Refer to par 7-12) + After remounting the engine, folowing adjustments eve aceseary, * Throttle eabie ply... Page 213 + icing speed. aan Page 2-12 + Drive chain — Page 2-14 * Rear brake pedal hight and fee travel... Page 217 + Pour 1.200 mi of engine ol SAE 10W/40 graded SF or SO into the engine afer overhauling engine. Startup the engine !and alow it un for several seconds et ide speed. About one minute after stopping engine, check of lave tho love is below the Lower line, a ol unl the level reacnes the *F™ lina, Refer to page 2.11) ENGINE DISASSEMBLE “The procediue for engine disassembly Is sequentially explained inthe folowing stops. 1+ Remove the Kok stator lever, + Remove the ol coale spe ‘Remove the oylinder head cover. ‘Remove the sparkplug «+ Femove the vale tiring inspection plig and generator cover pig ‘Turn the cranishat to bring the “T* line on the generator rotor tothe center of hele nore ‘When remove the camshaft the piston must beat (720) ‘on comprassion stroke +s Ramove the cap and inser the ©) screwdriver into the slotted en of the eam chain tension sojuster and turn it ‘locense to look the sping tension 1 Remove the cam chain tension adjuster ‘+ Remove the camshaft holders8-7 ENGINE ‘Remove the camshafts. intake @ and exhaust 2) «Remove the cam chain guide (3). ‘Remove the engine oll pipe with bots and washer. + Remove the eylnder head nuts ‘Remove the oylnder head by removing the bots + Remove the oylinder by removing the nuts + Romove the ovinder gasket += Place a clean rag over the cyindor base to provent piston in cep rom dropping inta the crankcase and then, remove the piston pln cicip witha long-nose ples « Ramove the piston pin wth the speci! oo (BD ceete-sest0:Pieton pin puller ‘Remove the piston «+ Remove the crankesse cover ‘CLUTCH ASSEMBLY (pages 9-8 and 3-9) 1 Remove the clutch cover. “+ Remove the eluteh epring mounting bots In a cxss-cross manner, and remove the springs and pressure plato ENGINE 3-82-9 ENGINE “+ Remove the clutch ceive and civen plates, ‘+ Fattn tho lock washer and remove the oth seo hub ut with the gpecial took (GB) 00020-55740 :citch sleeve hub holder + Remove the washsr( and primary even gor easenty(2) + Remove the spacer @) and washers @) + Remove tho geri shat @, + Romowe the gearsit cam plate @) by removing the bot). revo the gears cam stopper am (8) ‘+ Flemove the primary cive gear nut with the spacia toa (09910-20118 : Conrod holder «Remove the primar ve gear) ol pump ven gou@)by remove te oop and key @) «+ Femove the ol pump seve gaa). + Remove the ot sump wt pin @) + Remove te lancer shat ot and masher {BI v10 20118 : Conred holder ENGINE 3-103-11 ENGINE ‘Remove the generator cover famove the generator rote rt withthe spell tol (EB) 00000-44550 : Rotor holder Remove the genertor rotor with the special too (00890-4951 : Rotor remover + Reve the can cio chain @ '* Remove the cam chain tensioner guide (2), * Ramo tha gener rior key @) ENGINE 9-42 + Remove the oi sup titer ©. ‘Remove the goar positon switch 2). ‘ Raove the ol seal retainer + Remove te gear positon swteh contact @), soi ove @ ‘Remove the spacer (2) + Remove tha crankcase bots arate the right and left crankcase with the spacial too! 09020-19120: Crankoase separator No nen using the epecl tl use the socket and primary cio gear nut © 10 prvert the ol jt on the erankahan «Rumor the gears fk sats @). @.« gait forks @.® sd guarsit cam3:13 ENGINE ENGINE 8-14 + Rerowo the transmission asembly ENGINE COMPONENTS INSPECTION AND ‘SERVICE nah ey ‘CRANKCASE BEARING AND OIL. SEAL i BEARING INSPECTION Rotate the Bearing inner race by Sager to inepect fo abnormal | play, noes and smoot rotation wile the besings are inthe crackcase Replace the besing Inthe flowing precede there Is res] ‘+ Flemove the Kick starter shaft with klek starter drive gear by tum counter colokwire the kick starter shatt [AcauTion] UE ‘the kick starter install to the Kick starter shaft only ‘+ Remove the crankshaft balancor evan ger with shat ‘sfaemove the crankshaft withthe spacial tool (9020-13120 : Crankshaft remover (Crankease remover) ‘anything unusual ‘Remove the bearing retainers, Femove the of saa withthe epecal tool, (09019-50121 : Oil seal remover AcAUTION ‘The removed oll seals should bo replaced with new «Remove the washer @ move the bearings wih the spacial tol (Ey 0919-75520 : Bearing remover (Bearing installer) 09019-75610 : Bearing romover (Bearing installer) 09019-75821 : Bearing remover (Bearing installer 9922-55191 : Bearing remover (Bearing installer) (09049-88211 : Bearing remover (Bearing installer) [Acaurion The removed bearings should be replaced with new ones.3-15 ENGINE ‘Install the new bearings to the right and left crankcase with the special fools B} 09913-75510: Rearing installer (09918-75821: Bearing instator 09019-70010; Bearing installer ‘Tian the bearing retainer sorows to the species torgun [8] Serom: 6.8 nem (0.85 kg-m) ‘+ Apply a small quantity of SUZUKI SUPER GREASE “A” to the tip of the oll seal, {98000-25010 : SUZUKI SUPER GREASE “A” + instal the new ol seas to the crankcase. 09019-75821 : Bearing installer CYLINDER HEAD ‘Remove the intake pipe, ‘Tho removed O-ring should be replaced with @ now ENGINE 3-18 + Remove the tappets and shime 7) with fingers or magnetic hanes + Compress the valve sping and remove tha to cotter halves Q trom tho vata etom with the peca tool 00016-14510: Valve liter (09016-14500 : Valve liter attachment 09016-04511 : Tweezers ‘+ Flemove the valve spring retaner, valve spring and valve serng seat + Pull out the vate from the other side.3-17 ENGINE ENGINE 9-18 ‘CYLINDER HEAD DISTORTION Decarbon the combustion chamber. ‘Check the gasketed surface ofthe cylinder head for dstorion with a straightedge and thickness gauge, taking a clearance reading at several places as indoate. Ith largest racing at ‘any postion ofthe straightedge excseds the limit, replace the coyinder head. ‘Service Limit: 0.05 mm 9900-20808 : Thickness gauge VALVE FACE WEAR ‘Measure the thickness (D) and, ifthe thickness is found to hhave been reduced to the limit, rplace the valve Nore Visualy inspect each valve for wear of its seating face ‘Replace any valve with an abneemaly wom face. Service Limit : 0 mm VALVE STEM RUNOUT Suppert the valve with “V" blocks, a8 shown, and check te runout with @ dal gauge. The valve must be replaced i the runout axcoed the ln Service Limit: 05 mm (00000-20701 : Magnetic stand (08600-20606 : Dial gauge (1/100 mm) (08000-21906 : V-blook (100 mn) VALVE HEAD RADIAL RUNOUT Place the cil gauge at right angles to the valve head, and measure the valve head racial runout Itt measures more than Im, replace the valve Service Limit: 0.09 mm VALVE STEM DEFLECTION Lethe valve about 10 mem fram the valve seat. Measure the valve stem detection in two directions, "X" and “Y", perpen: lular 1 each other, by pesitioning the sal gauge ae shown, the Getaction measured exceeds the limk. then determine ‘ether the valve or the guide should be replaced with anew Service Limit : Intake and exhaust valves: 0.25 mm VALVE STEM WEAR iesasmaneabevenseseeneenane the vate stem f= wom our tothe limit, when measured wih a micrometer, ard the clearance is found to be In excess ofthe limi ncicated previously, replace tho val, Ifthe stem is within the limit, then replace the gules. After replacing valve oF guide, be suee to re-check the clearance, Valve stem 0.0. IN, 4476-4490 mm Standard eee EX 1 4455-8470 mm (09900-20205 : Micrometer (0-25 mm) Nore 1 valve guides have to be removed for replacement ator Inspecting related parts, camy out the steps shown in valve ‘guide servicing VALVE GUIDE SERVICE 1 Romove the valve guide with a valve guid remove. (09016-44510 : Valve guide remover Nore : * Discard the removed valve guide subassomblies, * Only oversized valve guides are avalabe as replacement pats «+ Re tinh the ave guide les in eyllndr hsad with a earner and hand (09016-24500 : Valve gulde reamer (10.8 mm) 0916-94542 : Hanalo nore: Inaert the reamer from the combustion chamber and eays turn the reamer handle cockwise. “Fit a fing to each valve guide, { Lubricate each valve gulde wit oll and dive the gue into the guide hole with a vave gulde install (09916-44510 : Valve guide installer ‘AcavTion] Te sree wo Faw ae gi ng an aNe98-19 ENGINE ‘Alter iting the valve guides, e-fnish their guicing bores ith the reamer and handle, Be eure ta clean and othe ides ater reaming, (09016-30210 : Valve guide reamer (45 mm) 00016.34542 : Handle VALVE SEAT WIDTH + Coat the vave seat uniform with prusian blue Fit the valve and tap the costed seat with the valve face in a rotating manner, In order to cbtaln@ clear impression ofthe seating ‘contact. In this operation, use the valve lapper to hold the valve baad «The rage dye ioresion eon he va face mut be coninious-vhout any Break nation, the wt ofthe 6 ng, vi i te ved oa wi, mst be hin he flowing speciation standord Vato seat with @ : 09-41 mm eer ecient not me, oct tha sat by soning as folove VALVE SEAT SERVICE Tho va seats for bth intske and exhaust valves are mn chine to fur efernt anges (To sat contact surface i INTAKE SIDE EXHAUST SIDE a5" Nest 45"] noat [a0 N26 3 190 eo" nant a _ (GB) 02010-21110 vavo saat cuter sot 00016-24410: Vaio eat cxttor(H-11) 06616-24480: Vaive seat cut (N-90) 28016-24470; Vote seat cutter (N91) ‘616-2060: Valve soa citer (N12) G616-20840: Sok pot (100-45) nore The vave seat contact area must be inspected after each cut « nser the sold plot @) with sight rotation. Seat he pilot snugly Install the 45° cutter, sttachmént and T-handle. ‘sUsing the 45"cutter, déscale and clean up the seat with one cor two turn, sinspect the seat by the proviously described seat wicth measurement procedure. the goat is pitted or bummed, ‘clonal seat corstoning with the 45°cuter fs required nore: Gut only the minimum amaunt necessary from the seat t0 prevent the possibly ofthe tappet shim replacement Ifthe contact area is too high on the valve or Hit is too wide, se the 15"eutter for exhaust side) and 30760" cutters (for intake si) to lower and narrow the contact aroa. Ir he contact are ie 100 low or too narrow, use the 48" cuter te ralea and wien the contact area ‘After the desired seat postion and width is achieved, use the 45 cater very ightly 10 clean up ary burs caused bythe previous cutting operations. [acaumion] ‘DO NOT use lapping compound after the final cut f= made, The finshed valve seat should have a velvety ‘smooth finish and nota highly polished or shiny finish. ‘This will provide a soft surface for the final seating of the valve which will occur during the frst few seconds [of engine operation. «Clean and assembie the head and valve components. Fil the Intake and exhaust ports with gasoline to check fo leaks. any leaks ocour, ingpect the valve seat and face fr burs other thiage that eould prevent the vale fom sealing PR ENGINE 3-20 ‘Cortact area to igh and too "Always use extreme cautlon when handling gasoline Nore : ‘After sercing the valve seats, be sure to check the tappet clearance after the cyinder has been reinstalled. (Reler to page 26)321 ENGNE None 6-20 VALVE SPRING — — Ck th epngs or erengt oy measur tha oe sini save pings making sie tat th dost tra aio te ce reed a congrce tur¥the Hat IOS) ean ap goes to et on ho ea a ile baby nceoed byte fe lah ving rg the mead foe doe etn whn te rang sched a replace the spring, Valve spring free length Service Limit: $8.69 mm (EB 02000-20201: Vernier catipers Valve spring tension Standard: 121-18. kg/33.7 mm REASSEMBLY ‘Install each valve spring saat + Lutwicato valve etm sea! with ol and prose the 2 postion with a fnger tip, [Acasrion] ‘Do nat reuse the stem seals ‘inert the valves, ith thelr tems costed wth (SUZUKI MOLY PASTE) all around and along the ful stom length without ary break Sicily ol the tip of the stom seat 99000-25140: SUZUKI MOLY PASTE Acaution \Wmen inserting each valve, take care not to damage the tin of the stem seal «Put on te vv spring retainer) and using the va ite, ese down the eprint ctr nes tothe stem er fand release the iter to allow the cotter @) to wedge in beeen retainer and stun, Go sur tat the rounded Ke a tho cotter fs snugly into the groove nthe stem en 09916-14540 : Valve itor 09016-1450 : Valve ifter attachment 09916-04511 Tweezers [AccauTion| [aie to vostore cach arn, wave, Sim ad ovr] to thei orca! postions. Nore ‘Apply engin ol tothe shim and taopet before titi them. ‘CAMSHAFT Both camshafts should be checked for runout and also for ‘wear of cams and journals if the engine has been noted. as ting abrormal noise or itation oF lack power output Any ‘ofthese condtions may be caused by camshafts wom down cor disortod to the saree bmi ‘The exhaust camshaft can be astinguished from that of Intake by the embossed leterEX" (for exhaust) 8 against HN (fr intake), Le9-28 ENGINE CAM WEAR ‘Woen-down cams are often the cause of mistined valve ‘operation resulting in reduced output power. ‘Tho limit of cam wear is specie for both intaks and exhaust came in tes of cam height @, which I to be measured vith Replace the camshaft if found it worn down tothe lint ‘Cam height (@) Intake cam : 34.660 mm Service Limit Exhaust cam : 84377 mm (GB) 02000-20202 : micrometer (25-50 mm) ‘CAMSHAFT JOURNAL WEAR Determine wheather or no ea oun is worn down 2 the lot by measuring the oi laarance wth the casa aed in plac, Use te pastignuge Qo read the deararce a he widest porn. ich ie ape as fotows: Camshah-Journal ol clearance (IN & &X) Seree Limit 0:60 mm 866022901; Postigauge nore: Instat each holder to ther orginal postions ‘Tighten the camshaft holder bolts evenly and diagonally to the specie torque, (Camshaft holder bolt: 10 Nem (1.0 kgem) Nore: Do not rotate the camshafts with the plastgauge in plac. ‘Remove the camshaft holders, and read the with ofthe ‘compressed plastigauge with envelope scale, This measurement ‘houid be taken at the widest part, - L Hf the camshsh Jou oll clearence measured exceeds the limi messi the inside ameter ofthe camshaft jours holder and outside clameter of the camshaft journal Replace the camhaft on the cylinder head depending upon which one exceods the specification Standard Journal holder LD. (IN & EX) : 2.012-22.095 mm (09800-20208 : Micrometer (0-25 mm) ‘Standard ‘Camshaft journal O.D. (IN & EX) : 21.050-21.080 mm ‘CAMSHAFT RUNOUT Measure the runout with aaa gauge. Replace the camshaft it the runout exceeds the Hm. Camchaft runout (IN & EX) Service Limit: 0.10 mm (08800-20606 : Dial gauge (1/100 mm, 10 mm) (09000-20701 : Magnetic stand (08000-21904 : V-black (100 mm) EXHAUST CAMSHAFT/AUTOMATIC DE-COMP, ASSEMBLY ‘Move tha automatic de-comp. weight by finger to Inspect i ‘operating smoothly. it does not smoothy mast be ccamshat/automatc de-comp. aasombly. 200d with a now exhaust carrion] Do nat disassemble the automatic de-comp, assombly. is not serviceable. ENGINE 3-243-25 ENGINE CAM SPROCKET When instaling each cam sprocker tothe each camhat nthe contrary notch(A) and aw matk No. (3) on INTAKE cams, or notch) ae ow marc Nod and 3 @ on EXHAUST camshat, + Apply THREAD LOCK SUPER “1908 to the threads of cam ‘sprocket bots, and tighten them tothe specie torque 8D 90000-22050 : THREAD Lock SUPER “1303° TB) sprocket not: 14 sem (1 ko-m) ‘CAM CHAIN TENSION ADJUSTER Tho eam chain tension adjuster ie maintained at the Bropertension by an automaticaly adhuted tensioner. Insert the C) serewcrver into the aoted ond of cam chain terion adistor and tum it clockwise to lesen the tension fd reas the ©) serowever fom the cam chain tangon sxuter. to make sre the pushrod movement. the push eo is stu or pring mechariom fale, replace the cam chan tension ecustarassombly with anew one CYLINDER, DISTORTION Check the gasketed surface ofthe cylinder for distortion with 2 sraightadge and thickness gtuge aking a clearance reading at Soveral places as indcate. If tho largest reading at any Poston of the stalghtedge exceeds the it. eplace the cyinda. ‘Saryico Limit: 0.05 mm 09900-20603 : Thickness gauge CYLINDER BORE Measure the cinder bore clmeter at sx places, any one ofthe measurements exceeds th iit overhaul he ‘onder and replace te piston with an oversize. or replace the coving, Service Limit : 62065 mm (09800-20508 : Cylinder bore gauge set PISTON AND PISTON PIN DIAMETER Using @ micrometer, measure the piston outside cater at the place 15 mm from the skit end as shown in Fig the measurement isles than the Fr, replace the piston, ‘Service Limit: 61.908 mm Piston oversize : 05, 1.0 mm GED 09000-20208 : ticrometer (50-75 mn) PISTON-CYLINDER CLEARANCE ‘sa result ofthe above measurement, the pston to cylinder Cieerance exceeds the felling leit, overhaul the eyinder ‘and ute an oversize peton or replace both eyinder and piston. ‘Service Limit 0.120 mm PISTON RING-GROOVE CLEARANCE Using a thickness gauge, measure the side clearance of the ‘stand 2nd rings. f any of tho clearances exceeds the lini op08 bath piston and piston rings. Piston ring-groove clearance tet: 048 mm Senice Lint and + 018 mm Piston ring groove with “ot? 101-168 mm Standard and : 101-108 em Ot: 201-208 mm Piston ing thickness Standard fat and 2nd: 097-099 nm {EB} 02000-20808 Ticknoss gouge ‘8000-20208 ; Micrometer (025 mm) Nore: Using a eot-metatsraper decarban the cow of he piston Gieon the ng aroves iio PISTON RING END GAP Fit the ring in the cylinder, and measure each Ying end gap sing @ thickness gauge. Ir any ing nas an excess enc gap, reslace the rng Piston ring end gap Service Limit 4st and 2nd : 0:38 mm (09900-20609 : Thickness gauge ENGINE 5-263:27 ENGINE PIN BORE Using caliper gauge, measure the piston pin bore inside ameter, and using a micrometer measure te piston pn outside ameter. the diferonce between these two measurements is ‘more than the lis, resace bath piston and piston pi, Piston pin bors ‘Sorvice Limit : 16.030 mm Piston pin 0.0, Service Limit : 18.980 mm CRANKSHAFT AND CONROD py @ Ges CONROD INSPECTION CONROD SMALL END 1D. «Using a caper gauge, moasur the conrod small énd inside ameter. Service Limit : 16040 mm ED oxo. 20505 vat caters {the cowed anal nd boi amet exceeds hei felce caved ENGINE 3-283:29 ENGINE CONROD DEFLECTION AND CONROD BIG END SIDE CLEARANCE Wear on the big end of the conrad can be estimated by checking the movement of the small end of the rod. This ‘method can algo check the axtent of waar onthe pats ofthe conrod's big end ice Limit : 20 mm (09900-20701 : Megnetie stand (09900-20606 : Dial gauge (1/400 mm) (9900-21208 : V-block Push the big end of the conrod to one ede and measure the de clearance with a thickness gave. ‘Standard : 0.10-0.45 mm ‘Service Limit: 4.00 mm (09900-20809 : Thickness gouge Where the iit is exceeded, replace crankshatt assembly oF reduce the detection and the side clearance to within the lt by replacing the wom pars-coneod, big end bearing ard ear pin ete, CRANKSHAFT INSPECTION (CRANKSHAFT RUNOUT ‘Suppor the crankshaft with "V" blocks as shown, withthe two fend jours resting on the blocks. Poston the dal gauge, 25. shown, and rotate the crankshaft slowly to read the runout Corrector replace the crankshaft if the runout is greater than the leit ‘Service Limit : 0.08 mm REASSEMBLY + Decide the widtn between the webe refering to the flows below when rebuilding the crankshaft Standard width between webs : 6307 0.4 mm ENGINE 3-30 (CRANK BALANCERSHAFT AND GEAR — @ piven gear @ sxtng 2 ve) @ Baarcors damper © onetp DISASSEMBLY «Remove the balancer from th ‘sRamove the cxcip @) «Separate the crven gear). balancer damper(2). sping @) and wave washor @)9-91 ENGINE lnspe the balancorshatt and key wear or damage. REASSEMBLY ‘neta the wave washer © avn gear @ sering @). Balancer damper @) eae ‘+ Reassemble the balancer shat inthe reverse order of ‘essceroy ‘TRANSMISSION DISASSEMBLY «+ Disassorbe the tranemiasion gears as shown inthe stration. Nore men removing the 2nd dhve gear, uso @ gear pul nd a proper attachment om ENGINE 9-32 COUNTERSHAFT AND DRIVESHAFT REASSEMBLY ‘Assembie the countershaft and diiveshaft In the roverse order of disassembly. Pay attention to tho following points. nore: gee ntlng the ger, as Sohty MOLY PASTE o engine of the esha ant coun “Alin 2200025140 SUZUKI MOLY PASTE Acaurion| 7 Never reuse a crip, After a orlip has been removed from a shaft. it ‘a new circ must be installed + When installing 8 new ciroip, care must be taken not to expand the end gap larger than required to sip the elrlip over the shaft « Alter instaing a crcip, always insure that i i¢ completely seated in its groove and securely ‘ited hould be seared and «Wan instaing a new clip, pay attention to the rection of ‘he cicip. Fit it to the aide where the trust is as shown in _ the flow 2nd DRIVE GEAR 1 Press fitted 2nd drive gear onto the countershatt. Before reassering, coat the internal face of the 2nd crve gear ‘ith THREAD LOCK SUPER "1903" end install so thatthe length As 25 shown. Counterstattnath @ £880 ¢ °° nm (ow to 2nd) ‘6 91000.22000 : THREAD LOOK SUPER "1903" NOTE * Take care not to smear TOP dive gear with THREAD LOOK SUPER "1308". + This procedure may be performed only twice before shaft replacement is require9-99 ENGINE ENGINE 3-34 GEAR SHIFT FORK Using a thickness gauge, chock the shi fork clearance in the 1008 ofits gee: “This clearance foreach of he two shit forks plays an important role in the smoothness and postivensss of shifting action Each fork has its pronge fed Ino the annular groove provided in ts gear. In operation, there is sliding contact between fork ‘and gear and, when ashing acon is nat, the fore pushes the goa’ axially Too much a clearance is, tereore, fable to ‘cause the meshed gears to stip apart. I the clearance checked Is noted to exceed the lt specie, 12 tha fork oF ts gear. or both (99900-20803: Thickness gauge Shift fork-groove clearance Service Limit: 08 mm Shift fork groove width Not $5051 mm ‘Standord No2 :5556 mm ‘Shift fork thickness Not: 48-49 mm Standard No2 :5354 mm PRIMARY DRIVE GEAR. DISASSEMBLY «Remove the primary deve gear trom primary shat. «ntl the key, primary gear, washer, spring washer and nut3-95 ENGINE CLUTCH CLUTCH DRIVE PLATE Measure the thicknass of each eve plate wih verier capers. Replace dive plates fourd to have wom down to the limi. Service Limit “Thickness: 26 mm haw with: 11.0 me (99900-20102: Verner calipers ‘CLUTCH DRIVEN PLATE Moacure each ven plato for cstocion with a thickness gauge Replace driven plates which exceed the limi ‘Service Limit: 0:15 mm (6B) 02000-20208 : Thickness gauge ‘CLUTCH SPRING FREE LENGTH Measure the treo length of each col sping with a verier calipers. and determine the elastic strength of each, Replace ary spring not within the fit Service Limit: $1.0 mm BD 00200-20102 : Vernier calipers CLUTCH RELEASE BEARING Inspect the release bearing for any abnormality, particularly cracks, to decide whether It can be reused or should be replaced ‘Smooth engagement and disengagement of the cluten ‘depends much on the coniton of thie bearing, ENGINE 3-36 ENGINE REASSEMBLY FReassemble the engine inthe reverse order of ds precauttonary measures should be taken, assembly. The following stops requ special attention or Nore : ‘Apply engine ol to each running ane sing part betoreresssembng (CRANKSHAFT «When instaling the crankshaft into the crankcase itis neces ary to pli left end into the lft crankcase wth the speci tools iy engine ol tothe crankshaft beerings. 99010-22812 : Crankshaft installer (09810-20116 : Conrod holder (09011-11910 : Attachment enurion) ‘Never install the shaft into the crankease by ania | Wrasse rar Anos tree spa otherwise erankshatt alignment accuracy wl be affected. CRANK BALANCERSHAFT 1 Aig the punched mark(i)anthe crv goer wih te punches mak onthe cen gear ‘9-97 ENGINE «ig the pnch marc @ of ck starter wth punch mak Got Wek tre shat «Tum the kick starter shaft counterclockwise and then look to kick starter with Kek starter guide. Inst he ick starter dive gnar @) wave washer @ Ant wasner © with starter sha a GEARSHIFT CAM AND FORKS + insta he taneision assembly ‘Instat the gearoit fos and gears cam. QD :cecrshit tok Not : coats for Noz s int tho geri fon stats (@D) «Wipe the crake mang surfaces (pth suiaes) wth a cleaning sot «Apply SUZUKL BOND NO.125 to the mating srtaco ofthe ht crankcase, 23) 90000-91110: SUZUKI BOND NO.1215 ENGINE 3-38. 4 Ft tha done! pine (ort theif haf of the crankcase. {Apply engine oto cored big end ane vansmsson gear. « Aasomble a craanas within fw ints {Tagan ne caricase bots ofthe specie trae [E} crankcase bot: 10 Nam (1.0 kom) Nore + After crankcave bolts have been tightened, check of orank shaft rotate smootiy. + Ira large resistance i fat to rotation ty to foe the shafts by tapping the cive shat or countrchat wit aplastic hammer,3.99 ENGINE ENGINE SPROCKET SPACER ‘s Apply SUZUKI SUPER GREASE “A" to the Oxing t andip@) of ol eal and instal the engine sprocket spacer ento the ctiveshat (xcarron] Use the now Ovrna ‘+ Inta the oll seal etane. GEAR POSITION SWITCH @ ‘ita the spring @) and contact @ and new O-tha ©. «natal the gear position switch, CAM CHAIN, CAM CHAIN TENSIONER AND GENERATOR ROTOR «+ Engage the cam chain D ono the cam dive sprocket ‘natal the cam chain tensioner) and tighten the Blt. + Dogrte th apred pron fhe cranks an a he senor oe Pith toy @) sal he goer tor ses {hop THREAD LOCK SUPER “T008 to te generac flor tut ard ren tote opcode with te ep fo EB 0000-22000 : THREAD LOCK SUPER W180" B® ow0s0 44512: Rotor holder TB) conerator rotor nut: 80 Nem (80 kon) ENGINE 9-40 ow ser “inca ths ol et a ahown fh ptogoh BALANCER SHAFT BOLT ‘ramon th bara eat ott th specie oe ng the pei fo 2010-20115 Cnrd hair TB stoner shat bot : 50 N50 kom) OIL PUMP AND PRIMARY DRIVE GEAR 1s Apply engine oi tothe afding suraces of the ol pump case, outer rotor, Inner rator and shaft, before mounting the pump ©. «Apply a small quanthy of THREAD LOCK "1942" 10 the ol pump mounting screws, and tighten them. GB) 99000-82050 : THREAD LOCK “1942” ‘sta the pin @, «Install the oll pump drive gear (3) and oll pump driven gear wan the ceolo @) s rsta the key © and primary sive gear: nore: Primary ive goar@) a show in the Wastin3-41 ENGINE ‘natal the washer ©) spring washer (and primary dive gear rut (@ a shown i te hustaion. nore: 1 rina out @ has ot hand reac Tighten the nt tha speed torue. [5] Primary rive gear nt £0 Nm (50 ko-m) GEARSHIFT SHAFT AND RELATION PARTS. + Aety THREAD LOCK SUPER “1800 to the toads of ert cam ppe am Sh nd ie ote peo ‘coe ‘cD nco-saa ; THREAD Lock SUPER “100" TE) coast com stopper rm ht: 1 hn (1.0 bg «+ Aign the hale @ of gars car plate with pin @) of serait cam «Tiahten the gearohit cam plata bott @) tothe epsctied toraue () coarshirt cam plate bolt: 40 N-m (1.0 kg-m) ‘EB 20000 20000 : THREAD LOCK SUPER “100° «neta the washer @ ont the gearshit shat. ‘Ineal the geereht shat assombiy to the evankoase. “Fe gsareitepring (6) tothe goarshit ae storper @) cone NOTE: When replacing the gearshit am stopper @). apply a smal ‘quantity of THREAD LOGK SUPER *1303" tothe tread off ‘and tighten to the specified torque 90000-22000 : THREAD LOCK SUPER “19007 [B) Gesrehitt arm stopper : 19 N-m (1.9 kg-m) ENGINE 9-42343 ENGINE ‘CLUTCH + lata the washer @ ane spacar(2) onto the counters Nore: ‘Apply engine oll to the inside and outedle surfaces of the spacer «oot the peemary dven gear a @ ont the courtershat bly and thrust washer nore : When engaging the primary ove and driven gear, tua the primary criven gear assembly to the counterclockwise + Inotall the clutch steve hub and lock washer D> [Acamnon]| Tit the tongue (@) of Tock washer fo the flat portion of thtch sleeve «instal he clutch sleeva hub nut, angen tothe spaces torque with the special tool, oan 55740: Ctch sleeve ib hdr [B)_ cate seeve nb ut: 89 Hem (50 Kam) « Lock the clutch sleeve hub nut by femly bend the tongue of the lock washer neal the cutch deven and other ie plates one by one into the con leave hub. «instal tho cut ease rack) eating @ presse plate © the eaten shove hus nore: "Trace th oer bearing Bidet he outch release rack * Ma sur that be cle pressure pate core. «+ nta the clutch springs and bolts onto the clutch presse plate «Tighten the botisclagonaly ENGINE 3-448-48 ENGINE « instal the two dowel pins and new gasket ‘When instalng the clutch cover, face the clutch release rack to the pinion gear side. « Tghton the cutch cover bots to the specie torque. [B) ctsten cover bot : 10 Ne (1.0 kgm) PISTON AND PISTON RING ‘« Install spacer(1) into the bottom ring groove first. Then install Both side rue (2). one on each side of ho spacer. The spacer and ice rae do nt havea pectic top or btm tine they ae now hon reaserbing used part insta thom in thar gina ple and reston. AcauTION 1st ring nd ing dle nthe shape of ing face and tho fave of fst rng le ehreme-pltad whereas that of 2nd ing Is not “he color of 2nd ing spears carer than that ofthe tt ing «1st and 2nd rings have the letter "A" and “RN marked on the top. Be sure to bring tho marked sie tothe top when fitting them to the piston «Position the gaps of the thee rings 9s shown. Bafore inert Ing piston into the eying, check thatthe gaps ae so lost. tm nr a i to ti a eee cara OLY PATE ose ee are nao per a rn en ag crt etn be Pa eeeenore aa fAcason] Tow pan oe ree Se staan areata bopmoriecTo ofa es araip alors INCORRECT ENGINE 3-46 rhe [pee | connect L © Uoper ede T sete347 ENGINE CYLINDER ‘Botore mourting the eyindr block, ol the bg enc and smal nd of the cond and also the sling ourface ofthe piston, + Fit dowel pins to crankcase and then ft new gasket. /AcauTion ‘To provent cll leakage, do not use the old gasket again, aways use a new one, ‘+ Hold each piston ring with the piston ring section properly ‘and ingot them into the oylnder, “+ Check to ensure thatthe plston rings are propery inserted Into the oyiner si ‘Temporary tighten the cylinder base nuts. Nore : When mounting the cylinder, keep the camshat civ cha taut The camshaft chive chain must not be caught between cam chive chain sprocket and crankcase wien erankshat is rotated ‘CYLINDER HEAD + Ft the dowel pine tothe eyinder and then, attach the new gasket 10 the eying. [Accaution ‘Use a new eylinder head gasket to provent ol leakage + Pac oye eed on he hn {Totten te oyiner need boa of epee vosap ‘gi wth a tena wrench soa. TB cater ead bot Ita 9 Nom (9 kom Fa 25 thn (28 Hom) Nore: Aeply engine of to the cylinder head bots washers before instlng th coder head bats 1 Ater fil Sohtering the ener head bot tighten the cxtnder base nuts (7) and cylinder had nate tothe sect ore Oyinder base nut @): 10 Wem (10 ko-m) Cyiner ead mut @) 10 Nem (1.0 kam) ‘CAMSHAFT «Tur the crankshaft counter clockwise, and aign the" kine @ on the generator rotor with the index marke (@) on the crankease keeping tha camshatt deve chan pulled upwarc Acaution| 1 crankshaft Turned without drawing the comhat rive chain upward, the chain will be eaught between crankcase and cam chain drive sprocket NOTE: * tt Boor placing the camshaft onthe einer hea. apoly ‘SUZUKI MOLY PASTE tots ural, uly coating each jor twit topes tatrg care rot © kav ay By set ADDiy ne ft the camshat june! holsers “ARGH 90000-25140: SUZUKI MOLY PASTE each carat onto the corect poston. ("EX for exnaust se and "IN" i for eke si) “0h T Sne accurately lined up withthe index mark nokd the camshaft steady and lightly pul up the chain to remave the slack botween tho crank sprocket and exhaust sprocket «The exhaust sprocket bears an arow marked *""inccated “Tum over the exhaust camshaft so that the arrow points ‘lua withthe gaskoted surface of the cyncer head, Engine. the cam chain with this sprocket, The other arrow marked "2" is now pointing straight upward ‘Count the chain ol pin toward the intake camshal, starting from the roller pin dectly above this anow marked "2" and ‘ending with the 16th roler pin. Engage the cam chain with intake sprocket, loating the 161 pin tthe above the arrow marked “Son the inake sprocket nore The cam chain is now dng on al twee sprockets, Becartul ot to disturb the crankshaft unt the camshaft ourat holders ‘and cam chain tension adjuster aro secured3-49 ENGINE ‘Install the eight dowel pins. + Place each camshaft holders and carn chain guide onto the ‘correct position. Nore Carntat holder marked “EX or Ea er phat side an “Wor ae forint sie «Ten the cars older bots the specie tore {B) camshaft older bot: 10 Nem (1.0 kam) «instal a new gasket and the cam cla tenon adit to the etndr wth to two Bos and tien ther fo he speed tora [B} cam chan tension auctor bot 0. (1.0 Kam) Note: "Before insating the cam chain tension adstr lock the tensian sping wit a ©) serowdhver ad tu clockwise + Before insaling the cam chain tenion aluster, tun the Crankshaft normal drecton to remove the cam chan slack between the crank sprockat and exhaust sprocket «for instling the carn chain tension adjuster, tr sorenciver counterclockwise As the slotted of the cam chain tension acjustar tums, tne tension rod is advanced under spring force end pushes the cam chsin tension asjustor tthe cam chain. \dvcauTion]} [After installing the cam chain tension adjuster, check a sre tat the acutr work proper by hocking (8) Enaine cit pipe bott : 20 N-m (20 kat) «Lubricating of engine oil in each oll pocket in the esincer head, Nore Turn the crankshaft and check that all the moving parts such ‘as cam folower, camshaft. work propel [dacavmion oe. eter to pone] ‘Be sure to check the tappet clearance. (Refer to page 25) ENGINE 3-503:51 ENGINE + Aoply SUZUKI EOND NO:2078 tothe cam end oap of he gasket 28 shown. G5] 00000-31140 : SUZUKI BOND No.12078 + Place tha eylindar head cover on the cylinder head. ‘= Apply engine ol to both side of head gasket en it them to the head cover bots [AcauTion [ Replace the gaskets with new ones to prevent ll leakage, | * Tahten to hand cover bos othe opctiod two sap torque [F) ontnder non cover bot: na 10 hem (19 keen) Final 14 Nem (14 kg-m) GENERATOR COVER «stl the dowel pn @ and new gasket @ «Tighten the gererater cover to the specified torque [By cenerator cover bot : 10 Nem (1.0 kg-m) ENGINE 9-52 ‘lL COOLER INSTALLATION ‘install @ paw O-ring ‘Apply enging oll to the O-ra. «Apply THREAD lock 10 the bolls. nstal he i cooker pipe «Tighten the ol cooler ose Bott the specified tore. SB sccuo-satto: THREAD LOCK SUPER 1942" {Bot cooter hose bolt: 10 nim. (1.0 kam) + instal the oll cooler bracket. + natal the Wik starr:CONTENTS FUEL SYSTEM... - FUEL TANK FUEL VALVE AND FUEL LEVEL GAUGE. REMOVAL neni 7 REMOUNTING eres = (CARBURETOR. : = 7 ‘SPECIFICATIONS ow a 1D. NO, LOCATION enews - CONSTRUCTION. DIAPHRAGM AND PISTON OPERATION nn SLOW SYSTEM rss MAIN SYSTEM nnn STARTER SYSTEM oo ennnsnnnrs FLOAT SYSTEM, Z = CARBURETOR REMOVAL nponnnsnm ‘CARBURETOR DISASSEMBLY... = CARBURETOR JET INSPECTION nnn NEEDLE VALVE INSPECTION. senna FLOAT HEIGHT ADJUSTMENT. CARBURETOR REASSEMBLY AND REMOUNTING.- LUBRICATION SYSTEM AND COOLING SYSTEM... (OIL PRESSURE. coe COIL, SUMP FILTER nnn ENGINE LUBRICATION SYSTEM CHART. 44 410 410 an on BAY an ANY at ant 424-1 FUEL AND LUBRICATION SYSTEM FUEL AND LUBRICATION SYSTEM 4-2 FUEL SYSTEM Winen stating the engine, © negative preseure (vacuum) Is generated at the intake pon. This negetive pressure crave on the Tua valve claphragm, (hough a passage way in the carburetor intake pina) and ‘vacuum hose, Oue te tig, the negative pressure increases hind the ual valve claphragm, un its higher ‘han the valve spring pressure. The vave in the fuel valve Is then foreed to open (due to this dlaphragm ‘operation and allows fel to flow into the carburetor fat chamber. FUEL TANK, FUEL VALVE AND FUEL LEVEL GAUGE REMOVAL “Remove the frame covers and leg shield. Retero page $2) {Remove the seat by loosen the nut Gi) Remove the fue tank mounting bots (2). | AWARNING| SS Nepetve pressure | oe re Gasoline ie vary explosive. Extreme care must be taken, «Remove the ul ank by dlcorneating to uel hese es ‘Necuum tose @) end ul eel gage la io couner@) { Rumowe te 5 vate @) {remove te fot eel omo9e @) FUEL FILTER REMOVAL «+ Femove the tame cover (se page 51) {rai the fuel by dlaconnectng the fuel nose @) {remove thet! Sitar @ fro the fet hose @)43 FUEL AND LUBRICATION SYSTEM INSPECTION AND CLEANING FUEL FILTER 1 the fue fiter i city wth sodiment or rt. ue vl not flow smoothly anc loss In engine power may resuit Clean the fuel fier with @ compressed ait FUEL VALVE ‘Connect the vacuum pump gauge tthe vacuum port ofthe {vel vaio as shown n the hustration, Apply negative pressure to the fuel valve and brow the fuel oulet por. I air doos not ‘low out. replace the ful valve wth a new one ‘Specified vacuum: 95 mm Hg SB) 09917-47010: Vacuum pump gauge Accaution Use @ hand operated vacuum pump. Do not apply high negative pressure to prevent the fuel valve damage. FUEL VALVE GAUGE REMOVAL 1 Open the seat, ‘oleconnect the te vel gauge lead wire coupisr @) {Remove the fel lve! gauge @) by removing the mounting For Inspecting the fue lovet gauge, reer to page’ 6-21 REMOUNTING ‘+ Peount the fue ank, ful valve and fue! level gauge inthe reverae order of comoval CARBURETOR SPECIFICATION fas Geena Carburretor type ~ (BS26-187 oa a ID.No- = 2560° ie in 700 00 oat 1a50 Tamm Han “00 det Needle | “4068 Teed PCH) Tt va “20 Pilot jot #126 Fiat = Sart “Trott cable play FUEL AND LUBRICATION SYSTEM &-£ LD. NO. LOCATION ‘The carburetor nad L0.(@) Number stamped on the carburotor body according to its specifications. CONSTRUCTION Qwest Qn Daphroom @ roe Gin om aa4:5 FUEL AND LUBRICATION SYSTEM DIAPHRAGM AND PISTON OPERATION ‘The carburetor is a vaiable-ventu type, whose vents cross section area is increased asa by bo ton vate (nth move scorn oe nga remeron te ‘down stream side ofthe votur @®) Negative pressure amit it hod carter tosh ‘an erice @) provided inthe piston valve @) raerarananarian ae ing negav presue overcomes the sping @) eres th sping @ force casing the itn vave Do to cent aiamiecaypect tea mayen county feaareayats wus page stn ‘oun conta bepote fos someon afr mothe ep te of tina ae LOWER POSITION OF PISTON VALVE UPPER POSITION OF PISTON VALVE | Qpraten vane Dovoeragm chanber Qorter << necurve presoune Qserng Denne | SLOW SYSTEM The sytem suppins fat cng engine opr Ti ot chamber is tered by the lt et (rs mitre, fw oo hen 088 ‘Aust dacharged into te man bore out of By-9a88 Pas eine and prayed out int te mah bore ou pot Q wore vate © Fost chanber @ Pre ot @ Prot aie @ Prt sow © By pas por © Prot ovter @ Pilot a passa | © outon @vave a MAIN SYSTEM fs tote vale Qs opened the engine spee Consequently te piston vale 2) moves upward eanofe fel fat chambers metered by mai i ven ikea with sr adit though ma a Jt ‘Te ented fe than pases tvough te clacance bot Cischarged no the vor nh inure proportioning 15 coo rms ow in age or smal, FUEL AND LUBRICATION SYSTEM 4-6 ation with trette vee sed or slgtlyepened The fol {@ whee rivas with ar coring in hough he pt it though, plot passage tothe pot sere (B) A par ofthe “ne remainer fs then wetored by plot aw Fae iste —_ 4 nes, an hs increases nogative pressure in the vert © ano retoe ue ters net et @) in to for on emusion. mn neo jot (4 and Jot needa @) and gina. vrotaned in newce jt 2) te ceararce tough which th emu! fe pending ultimately on trot postin. sich it meets main air stream being can by th eed _4-7 FUEL AND LUBRICATION SYSTEM STARTER SYSTEM Sling the choke lever ple staring phangee(])t draw fuel into the stata exc rom the feat chamber trough etaner jot @ Starter et @) mors tis us, and nies with the ai coming from the ft chamber. The tr, Fh in fool contort, reaches stating plunger and mies aga with te a coming through a passago externa from diaphragm chamber. “he two succoeserixings of fel witha are such thet a proper fur mitre to stating Is reduced nn the mur le sprayed ou through starter ate nto the main bore @ sarea phnaee Q state jt FLOAT SYSTEM The floats (and needle vave (@) ae sssoistod wih the same mecharism, 20 that, a8 th oats move up and down, | the neste vaive(@) too moves Heowise, When the fl level is up i he Hot chamber the floats @) are up ae the now valve @) remains pushed up against valve seat. Undor this conten ro fa entrs the foat chamber 1s the fl eel fala. the Moats] go down ane the now vaNe unseats Mas fo aor fue tothe chamber. i this manner, te needle vee (@) admits and shuts off ful tomate to mina a practical corsa fuel lve inde the fat chambec FUEL AND LUBRICATION SYSTEM 4-8 COASTING ENRICHMENT SYSTEM oor aing evhment ystems indysed inthe sow ester. ALthe rama anring operation ain of a oar poof he carefree to plot a passage which obs proper fea mitre cane eat vive f cowed sudden fargo nagatveprssuo C) gererated in he oyine a ne othe caperog 2). The wave) which foc with the prog 2) closes an ch win fuel This ejter to keep the combustion TW paseage thus, the fuel mre bacomes fen wth 2 ES ing the toa mite a by enaling wt he plot ct |4-9 FUEL AND LUBRICATION SYSTEM CARBURETOR REMOVAL «Remove the leg shield (Refer to page 5-2) {Loosen the clamp screws, “Remove the carburetor 1 Disconnect the ue! nose and vacuum hese @) [Gasoline is very explosive. Extrome care must be taken | «Remove the theta cabla @) fom te carburetor body. + Fema the starter plunger @) from the carburetor body. CARBURETOR DISASSEMBLY 1 Remove the carburetor top cap ©): + Rema the seriog and piston vate wth dlatvaam + Rornow tho jot neects @) fom the pston valve FUEL AND LUBRIGATION SYSTEM 4-10 « Remove the float chamber body. «+ Remove the gasket @. {Remove the foat assembly @) by loosen the serow and removing he vin @ « Remove the eeclevave assembly @ Nooate vaio © vave seat [Acaution] ‘+ Pemove the main jet ©) and pilot jet D> AcauTION [[Bo not use a wire for cleaning of passege and jets et) ure for cinaning of peewee = ‘+ Remove the needle jat @).4:11 FUEL AND LUBRICATION SYSTEM Remove the pile sir scrow D, nore: Before removing the plot a szrow D),daternina the setting by slowly tuning It locise and count te cunbr of us ruled to Kohl seat the screw. Ths counted numb i ‘portant whan reassemtng pt a screw oc posion. 1 Remove the tote valve) by rong the sr ‘These two serews are looked by punching thelr ends Once remaving the serews, they wil be damaged NOTE ‘Apply 9 small quant of THREAD LOCK "1342" to the sors, han intating tho throttle valve tots shaft 8D 90000-32050: THREAD Lock "1342" ACAUTION Face the stamped side of throte valve t outside ‘CARBURETOR JET INSPECTION Check folowing tems for any damage or clogging * Plt jt + Float * Mai jt * Noodle valve * Main ai Jet * Starter jot * Plot sorew * Gasket and O-irg + Noodle jt alr bleeding hola” Plot outet and by-pass holes NEEDLE VALVE INSPECTION I foreign mattr Is caught between the valve seat and the needa, the gasotne wil conte flowing and cause tte overom, <—§ > 1 the seat and needle ara worn beyond the permissible eit, sina trouble wil occur. Conversa, ifthe needle sticks, the ‘gascine wil rot flow Into the fest chamber. Clan the flat ‘chamber and float parts wih gasoline. It the needle is worr as shown inthe stration. replace It together with a valve soat ‘len the fel passage of ho ming chamber wth compressed a FUEL AND LUBRICATION SYSTEM 4-12 eigenen emenmeee FLOAT HEIGHT ADJUSTMENT “To check tho fot height, vat the earoucetor body. wth the thet arm kept fee, measure the height) while fest erm is inet contact wit needle vate by using capers. Bend tho tongue G) a8 necessary to rng he height to tis ve Fioat height @®: 1050.4 mm. EB) 02000-20101 : Vernier calipers CARBURETOR REASSEMBLY AND REMOUNTING FReaszomble and remount the carburetor aesembly in the reverse order of removal and disassembly. Pay attenton tothe flowing points: 1s Sot the throttle vale in such way that ite bottom end (&) reets the foremost by-pass (). Ths i accomplished by ‘uring tha throtle stop sorew. «Adjust the flowing items to the speciation Engine tele mi - Page 212 + That cable play : Page 213 LUBRICATION SYSTEM lL PRESSURE Rafer to page 221 lL FILTER Fefer to page 211, IL SUMP FILTER, ‘yen you replace the engine ol, check fo be sure that the ot sump fiteris fe trom ary sign of rupture, also wash the ot ‘sump fiter een periodical ‘Acaunon| [ Replace the generator cover geaket witha now one 10 | [prevent oitfeakage, (Peter page 0-12),‘CONTENTS EXTERIOR PARTS. REMOVAL oo - REMOUNTING..... = FRONT WHEEL... - ~ REMOVAL AND DISASSEMBLY cern INSPECTION AND DISASSEMBLY. sor REASSEMBLY AND REMOUNTING.. 2 FRONT BRAKE. a BRAKE PAD REPLACEMENT men BRAKE FLUID REPLACEMENT nme - CALIPER REMOVAL AND DISASSEMBLY... CALIPER INSPECTION 0s CALIPER REASSEMBLY AND REMOUNTING... MASTER CYLINDER REMOVAL AND DISASSEMBLY. MASTER CYLINDER INSPECTION. MASTER CYLINDER REASSEMBLY AND REMOUNTING. FRONT FORK. REMOVAL, AND DISASSEMBLY. — INSPECTION son REASSEMBLY AND REMOUNTING on n-r— STEERING... REMOVAL AND DISASSEMBLY... — INSPECTION oo mnsorn — REASSEMBLY AND REMOUNTING.. ~ REAR WHEEL AND REAR BRAKE 10m REMOVAL AND DISASSEMBLY. y= INSPECTION AND DISASSEMBLY... REASSEMBLY AND REMOUNTING. = REAR SUSPENSION, enn REMOVAL AND DISASSEMBLY nor - INSPECTION AND DISASSEMBLY. REASSEMBLY AND REMOUNTING..... :5:1 CHASSIS. chassis 52 EXTERIOR PART —— f. LEG SHIELD ® « Remove the cover center seen, ight an eos sorew@.@ 2 Let ' shield A «Remove the cover center @) ‘Remove th right and let lg shskss (2) ,@) FRAME COVER ‘pant sat wn te ignton key @) Remove th covr fame sow @)5:3 CHASSIS ‘Disconnect the brake ghtaligt cust. + Remove the right and ie tame covers @) REMOUNTING FRemount te frame covers and leg cles inthe reverse order of removal CHASSIS 5-4 FRONT WHEEL Benner OSS ay5.5 CHASSIS REMOVAL AND DISASSEMBLY FRONT WHEEL ‘Ralae the font wheel off the ground with a Jack oF wooden block + Pemove the axle nut ‘Remove the axle and front wheet + Femove the brake sc from the wheel by removing its bos INSPECTION AND DISASSEMBLY WHEEL BEARING Fate the Inner race by fingers to inpect for abnormal psy noise and smacth rotation while the bearings are in the whe Replace the bearing in the-folowing procedure ir theres anything unusual «Inset the adaotr of bearing remover to the bearing a8 shown, inset the wedge @) of bearing remover to the adapter tom the opposite side, look tho wedge inthe tof adept (By 0011-5011: Boaing remover + Dive out the wheel bearing by knocking the wedge. ‘+ Femove the remaining beating na similar way ith a suitable ber [Acarmon] “The removed bearings should be replaced with new ones. CHASSIS 5.6 WHEEL AXLE Using a fal gauge, check the wheel axe for rnout and replace iti emout exoeeds the limit. (09000-20605 : Dial gauge (1/100) (09900-20701 : Magnetic stand (09900-21904 : V-block set (100 mm) Service Limit : 0.25 mm WHEEL Inspact the whee! runaut Excessive runout Is usualy duo to wom or loosen wheel beer- Inge and can be reduced by replacing the bearings. f bearing replacement fas to reduce the runout, replace the whe, Service Limit (Axial and Radial): 2.0 mm5:7 CHASSIS chassis 5-8 REASSEMBLY AND REMOUNTING a FRONT WHEEL Resssemble and remount the front whea! and front brake in ‘Tighten the axle rut to the specified torque the reverse order ofromova and dlaassemby. Pay attention to ie [By ote rut: 53 Nem kom) the folowing points ‘ WHEEL BEARING + Apply SUZUKI SUPER GREASE “A” tothe bearing betoe stating FEB 2900-25010 : SUZUKI SUPER GREASE “A” “Pree ft the bowing to the whee with the special tot (EB) 00024-24521 : Bearing installer sot CAUTION | "First install the left whee! bearing, then right whee! bearing. ‘The seat side ofthe bearing should be faced to outside. | LS Left sido —————s-right side Lott side + right side @ Bearing neater st @ tot whos! bearing @ spacer @ pane whet bearing BRAKE DISC 1 Mako sure that the brake diac fs clean and free of any (sy mato Tighten the cse mounting bots t he epeeted torque. [broke cise hott: 23 N-m (2.9 kg-m)5-9 CHASSIS FRONT BRAKE ioe shan) SE Broun S Deore 2 § é /e » Ey By inne noon wi [rem] Nm [igm | Front brake moster ender bot 110 | 10 | @ Brake hose union bolt @) | 23_| 23 | © Brake caper mounting boit ae 26 | 28 | Qewe ad mounting bok & [ia] © Bake air bier vahe ssn ana san) RS "This brake system is filed with a ethylene glycol-based DOT 4 brake fluid. Do not use or mix aitferent types of tuid such oe siicone-based or petroleum-based, Do nst ne ay trae attr rom tend fom ud or nsx ora Never oe ke |eft over from the last servicing or stored for long periods. tote mit ‘When storing the brake fluid, seal tho container completely and keep away from children, “When replenishing brake fluid, take care not to get dust into ful. * When washing brake components, use fresh brake fid, Never uso cleaning solvent. A contaminated brake dise or brake pad reduces braking performance. Discard contaminated Pads and clean the dise with high quality brake cleaner or neutral dotergent. [Accaution’ Hanéle broke fui with care the Mud reacts chemically with pant plastics, rubber materiale to. [Handle rake fui with ar the id reacs chemical wth ait lst, ror mata, ee BRAKE PAD REPLACEMENT ‘oosen the brake pad mouring bots {rerove the caliper mounting bots @) «Remove the brake pa! mounting bots Remove tho brake pads [AccauTion] Do not operate the brake lever wi ismounting the pods. ‘Replace the brake pads 2s a sat, otherwise braking performance wil be adversely ffected ‘oneal the new brake pads ond ped mounting Bots {inten th brake calper mounting Bota (2)ané pad mounting bolts @te the epectid torus [B} Brake catoer mounting bok: 26 Nom 8 kam) Brake pad mounting bol 1 Nem (1.8 gm) nore ‘tor replacing the brake pads pup wth be brake over fer times to operate the bake corey and thn check the bake stove BRAKE FLUID REPLACEMENT «lon the meoryele on level ioe and Kop the hears sight Remove he master cylinder resent cap paste sheet and aptrage «Suck up the 0X brake fd as moch as posible Sa he resoroi with es Brake ful. eee “s Connact a cleaner hove @) to the alr blesder value @ and tot theo end of hoe into & recente «Loosen the Beacr vv app the brake evr uno tre od brake fut fows oof the lees aie «Gout a Boodle valve end aconeet clear hose Fi the rear wt ech fake fh othe uppar and of he inspeton window (AcauTion] Bleed air inthe brake fui eWruit. (Reter to page 216) chassis 5-105-11 CHASSIS CALIPER REMOVAL AND DISASSEMBLY ‘Disconnect the brake hose From the caliper by removing rion bolt and catch the brake fd in a suitable recep tate, ‘+ Ramove the caliper mounting botts @). [Acauron) Never reuse the brake fuld Toft over from previous servicing and stored for long periods, + Remove the brake pads, Refer to page 5-10) “Remove the bake Pad sping + Remove the caliper bracket (@) + Place a rag over the pistons to pravent ther popping out and push out the piston with an sir gun (enmon] [De not use high prossure air to prevent platon dama + Remove the dit seals @) an piston ® ‘Do not reuse the piston seal and dust seal to prevent | CALIPER INSPECTION Inspect the piston surface and caliper oyinder wal fr nicks, scratches or ater damage, CALIPER REASSEMBLY AND REMOUNTING Reassomble the caliper in the reverse order of removal and ‘Gsessombly, Pay attnton to the following points ‘Vash the caliper bore and piston with speciiod brake i Particularly wash the dst seal groove and piston seal groove, ‘Acaumion) Tan Be clprconpones wi ooh bea waren buna uge te anoanntsw “Nun wing compres pct thu nent te aterm tee ot ato ceeng stent nae von ee care «once te pstan aul and ieee! wi bw Mees ener econ, py mba te czas an preven ato instal he ew piston sols and dust seas. ‘esta oe pistons. { Apply SUZUKI SILICONE GREASE to the caliper exes GM 99000-25100 : SUZUKI SILICONE GREASE ‘insta the brake pace «Tighten the caliper mounting botts@)te the specified torque. {Tighten th brake oad mounting bots) tothe specie torque “sAttortouchng the brake hose union to the stopper @) tighten the union bolt @ to the spectied torque. [B} cater mounting bot (2): 26 N-m 26 kaon) Brake pad mounting bot (2): 19 Nem (18 ko-m) Brake hose union bolt (4): 23 N-m (2.3 kg-m) Nore Before remoynting the caper push the pistons all he way Into the catpar 1 Bleed ai from the air bleede valve after reassembing the caliper Refer to page 2-18) chassis 5-121 chassis Rake Disc serve the font whe. ele page 55) ily cbc he rake der danage aces eae thm ices wth a misortar Replace te cae te ‘herons nh ee inte anager Serie Lint Brake se ticks: 90 am Oo000 20008 remote (0:28 mn) Mire the not wih il gue fesac he ds he not exces et Senos Lit runout 03 mn (e000 2008 | a gage (17190 mn) deena 200%: Mgnt sane «ttn momureant rewire el the tela ce (otro pages 65 mee 0.5.7) «nt te tot wes tro bape 52) MASTER CYLINDER REMOVAL AND DISASSEMBLY + Remove the right rearview miror @) + Remove the brake lever (2). + Disconnect the brake ght switch lead wires (9) + Paco arg undemeath th rion Bol on he master yincer to catch ary spit rake fu. + Fomove the brake hose union bolt @) [A.cauTion] Immediately wipe off any brake Tid contacting any Part of the motoreyclo. The fluid reacts chemically with pain, plastics and rubber materials, et, and will damage the severely. + ong the master oid ste byron te wong vats + Romove the reservo# cap, pastic stl and daphregm. 1 Drain bake ful. + Remove the brake ight tc. 1 Remove the dust seat @) @ by vsing the special toot (GB) 02200-06108 : Snap ring pers «Remove the pitonieup @ and tum spring ©5-15 CHASSIS. MASTER CYLINDER INSPECTION ‘Inspect the master oyinder bors for any scratches or thor emage, ‘Inspect the piston surface for any sortahes orcther damage. + inspect the siston cup and dust seal for wear or damage, MASTER CYLINDER REASSEMBLY AND REMOUNTING Reassomble the master cylinder in the reverse order of removal and dlsassenbiy. Pay atention to the following points: [Acaution] = Wash the master eyinder compononts with fresh brake ‘uid before reassombly. Never use clearing solvent of ‘gasoline to wash them, }+Do not wipe the components with a rag, = Apply brake fluid to the eylinder bore components to be Inserted into the bo ‘Specification and Classification : DOT 4 Nore When fing the circ, make sue tha te sharp edge tothe Cirelp faces outside + When emounting the master eyinder en the hanclebar, ign ‘the master cyinder olde’s mating surface @) with punched mark @on the hanclbar an tighten the upper clamp bot fist a5 shown Master cylinder bolt: 10 Nem (1.0 kg-m) nore : ‘Be sure to face the "UP" mark on the holder tothe upside [Beamon] Bleed air from the air bleedor valve after reassembling ‘master oylinder. (Refer to page 2-16) FRONT FORK CHASSIS 5-16 @ Front fork ca bo cpemarey @ [2 [2s REMOVAL AND DISASSEMBLY + Remove the front whl. (Rafer to page 6.5) «+ Famove the front fender. oe ie «Remove the brake caliper and brake hove clamp. ander 1 Gieence Accavtion| ang the brake caliper on the frame with sting et, taking care not to bend the brake hose.5:17 CHASSIS. ‘» Loosen the front fork clamp bolts upper (7) and tower ‘« Remove the front fork. ie Nore : * Loosen the hancebar meunting nut end bot Bator removing the font fork * Sight loosen the font fork cap bolt before loosening Tower clamp bolt to facta later disassembly. + Remove he cap bot @) spacer @) washer @) and spring © ‘+ lver the fork and stroke «+ Hold the fork inverted fr few times to dean out fork ot nutes to drain ol «+ Remove the cust ea! D and stoope ng ‘sfemove the damper rod bol wth the speci! tools. rove tha inner tube from the outer tube (09940-34820: T-hancle (9940-04661: Attachment "D* (09000-00810: Hexagon wrench set «Remove the damper ved rom the inner tube ‘+ Remove the oil seal @. [Reason] ‘The removed olf coal shoud be replaced with @ new one INSPECTION DAMPER ROD RING «inspect the dernper rod ving () for wear or damage: FRONT FORK SPRING 1s Measure the fork spring free long. Hit is shorter than the service lit, replace it wih a new one, Service Limit : 401.9 ram CHASSIS 5-18 |5-19 CHASSIS INNER AND OUTER TUBE Inspect the Inner tube sling surface and outer tube alsing ‘surface for any scuting REASSEMBLY AND REMOUNTING RReassemble and remourt the font fork in the reverse odor of removal and dlsassembiy. Pay attention othe folowing points: ACAUTION * Wash each metal part with cleaning solvent before | reassembly. * Nover re-use fork oil aft over from the last servicoing. * Replace the oil seal and dust seal with new ones when reassembly «+ Aoply THREAD LOCK “1242" to the damper od bot and Sghen tote spcied torque wih the speci! os. (8 damper oa 25 tm 9 hem) SZ 20000-22050 : THREAD LOCK “1342" (>) 0n000 00410; Hoxagon wrench set 0040-4820; T-handle 060404561: Attachment “D" + Ista the ot soci @ withthe speci nore etre tang te of sean cust sea) appa sat uot of SUZUKI SUPER GREASE "A tothe tp oo So! ard cst set SH sooo 25010: SUZUKI SUPER GREASE “x7 (ED) 40-5800; Front ork o sa! star + neta the stopper sing @ snd dst seal. [AcauTion Make sure thatthe stopper ring @ fitted secur cHassis 5-20 1 Pour spocted fork 0 into the inner Woe. MGB Fork ot ype : Fork ofl # 10 -96000-96044-106 : SUZUKI FORK OIL # 10, Capacity (each leg) : 108.5 m Hold the front fork vertical and act the fork il level with ‘the special too (EB 04074111 : Fork ol lovel gouge (il Level: 160 mm Nore: When acusting te i evel, remove the fark spring ana comeress the Inner tube fly 10 ure to bing the smal demstor end of fork spring to the bottom. sna the ont fork ap bl to helene tbe. { ramount he font fork othe morc [Sette nig) ofthe ier ube upoerszfae 95mm from the steering uoper bracket. Then the front orc lower ta bots and ont fo cap bats @) tothe spootied tore Tighten the font fork upper elamp bots @) tothe spectiod torque Front fork clamp bolt: 23 Nem (29 ker) (upper & tower) Front fork cap bolt : 45 Nem (8:5 ko-m)5:21 CHASSIS ‘Tighten the hancleber mounting bots and us tothe spsciied torque. [B) Hanaiebar mounting bot and mut: 28 Ne (28 kgm) ‘+ Instal the front fender and tighten the front fender bot @) + ital the front brake caliper. (Refer to page ‘laste the font wha. (Refer to page 5-3) ‘+ Swing the motereycl up anc down several tine, ‘Tighten the front fender bots @) securely ‘STEERING '§ Se —onm Genk ued gasoine rcormardos Fon tank eect spas s2080 oar baka posal eit - Engle ol ype AE TOAT, APSF oF ar ook paca oe tl 535 Engine ot capciy ane To Taka die hicks Fant aaa? 30, Fir are 5100 Feet 237 30. ‘Ovtat 20m Bre dea nat as Font ofc ope Fork oF Masta ence be Frat emo 878 = Font foro cap eh es) 055 Rear "27000788 E Bake sd Wo ore ‘aster ends pion art Fret 12087-12664 : ear 12057-19808 7 Bee calor oyna’ Boe Font zzsoszr0 E