SUZUKI

RGV250

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 MANUFACTURE'S EXEMPTION
SUZUKI RG V250 HOP-UP KIT is a special-purpose designed for exclusive use in competition only on racing
course as distinguished from public road and highways. RGV250 HOP-UP KIT is not equipped for con-
formity with traffic law and regulations, and is not accorded with the benefit of product which SUZUKI
standardly grants on motorcycle of its manufacture.

NOTE:
* The motorcycle on which the HOP-UP KIT is installed, is not covered by the SUZUKI WARRANTY.
* This HOP-UP KIT manual describes only service specifications and servicing procedures which
differ from those of the RG V250 service manual,
* Specification will be changed without pre-notice.
* Please refer to the RG V250 service manual for details.

S&Z&m MOTOR C0.fLTD.

Sales Department E (for overseas)
Spare Parts & Accessories Division

©COPYRIGHT SUZUKI MOTOR CO., LTD. 1989

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 CONTENTS
SPECIFICATIONS 1
GENERAL INFORMATION 2
KIT PARTS INSTALLATION PROCEDURES 4
1. CYLINDER HEAD, CYLINDER, HEAD GASKET 4
2. PISTON AND PISTON RING 5
3. CLOSE RATIO TRANSMISSION 6
4. CLUTCH (FOR WET TYPE) 8
5. CLUTCH (FOR DRY TYPE) 9
6. OIL CATCH TANK 11
7. WATER CATCH TANK 13
8. CARBURETOR SETTING PARTS 14
9. MUFFLER REPLACEMENT 22
10. OIL PUMP REMOVAL AND BLINDING 23
11. SPROCKET REPLACEMENT 25
12. REAR SUSPENSION HEIGHT ADJUSTER BRACKET INSTALLATION 26
13. FRONT FORK 27
14. REAR SHOCK ABSORBER SPRING REPLACEMENT 34
15. FRONT BRAKE CALIPER PAD MODIFICATION 36
16. STEERING DAMPER INSTALLATION 37
17. SUSPENSION SETTING 40
18. SUSPENSION SETTING GUIDE 41
19. STAGE I KIT PARTS ELECTRICAL 42
20. STAGE II KIT PARTS ELECTRICAL 44
21. OTHER RECONSTRUCTION 47

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 SPECIFICATIONS
ENGINE
Type . . . . . . . Two-stroke, liquid-cooled
Number of cylinders 2
Bore . . . . 56.0 mm
Stroke . . . . 50.6 mm
Piston displacement 249 cm 3
Compression ratio 8.8 : 1
Carburetor MiKUNI TM34SS, Two
Spark plug . . N.G.K.: R5184-9.5, 10, 10.5

TRANSMISSION
Clutch Dry multi-plate type or
Wet multi-plate type
Transmission 6-speed constant mesh
Gearshift pattern 1-down, 5-up
Primary reduction 2.565 (59/23) [DRY CLUTCH 2.560 (64/25)]
Final reduction 46/13 (3.538)
46/15 (3.067 STD)
37/16(2.313)
STANDARD OPTION
Gear ratios, Low 2.454 (27/11) 1.875 (30/16)
2nd 1.625 (26/16) 1.471 (25/17)
3rd 1.235 (21/17) 1.222 (22/18)
4th 1.045 (23/22) 1.040 (26/25)
5th 0.916 (22/24) 0.926 (25/27)
Top 0.840 (21/25) 0.840 (21/25)
Drive chain TAKASAGO: RK520 TR-Z
D.I.D.: 520ERS

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 GENERAL INFORMATION
DFUEL
The engine is of two-stroke type, designed to run on oil~premixed fuel (when the oil pump is removed).
Fuel specification: Racing gasoline or aviation gasoline mixed with oil in the ratio of 30 : 1.
Oil specification : Motul 700E, Shell Sports SX (synthetic).

2) COOLANT
Coolant specification: Soft drinkable water
When filling the cooling system with water, follow the procedures below.
(1) Remove the radiator cap and pour water through the filler neck.
(2) Bleed air from the water pump.
(3) Holding the handlebars, lean the motorcycle two or three times to expel air trapped in the system.
(4) Squeeze each radiator hose to drive air away.
(5) Loosen the air bleed bolt on the side of radiator to remove air.
(6) Repeat the procedures (1) through (5) above until the water lever becomes constant.
(7) Fit the radiator cap securely.

After the above procedures are completed, start and warm up the engine, then check that there is no
water is no water leakage. Stop the engine, allow to cool and check the water level again.
• During the race interval, drain the system completely to avoid corrosion or other harmful problems in
the radiator and engine water jacket.
• The water temperature for best engine operation is 55 — 65°C.
When more than 70°C, considerable power loss will result.

3) WARMING UP
Always warm up the engine before running in the following manner:
(1) For 1 — 2 minutes, rev the engine up and down within the range of 5,000 — 6,000 rpm.
(2) For another 1 — 2 minutes, rev the engine up and down limiting the highest revolution to 8,000 rpm.
(3) When the water temperature reaches approximately 65°C, test drive for approximately 50 m and
check the operation of gearshifting, clutch, brake etc if an appropriate warming up site is available.
(If the water temperature rises to more than 90°C, check the system immediately because there may
be problems like leakage, insufficient water etc.)

4) BREAK IN
(1) New machine
Keep the engine speed as constant as possible during running. To shift up or down, keep to the following
rpm limits. Use as high gear as is practically possible.
a. First, run 2 — 3 times in the track limiting the engine speed below 8,000 rpm.
b. Stop and check for parts looseness, leakage etc.
c. Run approximately 30 km limiting the engine speed below 8,000 rpm.
d. Run approximately 20 km limiting the engine speed below 9,000 rpm.
e. Run approximately 20 km limiting the engine speed below 10,000 rpm.
The total of running distance is approximately 75 km.

CAUTION:
During breaking in period, run the engine on slightly rich carburetion.

(2) When parts replaced

• If the cylinder or crankshaft is replaced, the same break in as new machine is required (approximately
75 km).
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 • If the parts such as piston, piston ring, transmission gear are replaced, break in as follows:
For 20 km below 8,000 rpm
For 10 km below 9,000 rpm
For 10 km below 10,000 rpm
Total distance — 40 km

5) REPLACEMENT
(1) Scheduled replacement

PARTS OR ITEM RECOMMENDED CHECK REPLACE IN FOUND

Piston Every 500 km Wear, pitting
Piston ring Every 500 km Wear, sticking
Piston pin Every 1,000 km Seizure, stepped wear
Piston pin circlip Every 300 km Whenever disassembled
(Each time removed)
Piston pin bearing Every 500 km Seizure, wear |
Piston pin bearing washer Every 1,000 km Wear, scratches
Crankshaft Every 2,000 km Runout, seal damage, bearing wear
Transmission oil Initial 100 km and every 1,000 km Contamination, emulsification
Drive chain Every 500 km Stretch, kink
Fork oil Initial 100 km and every 3 races
Brake oil Every 3 months or after rain

(2) Other wear items to be replaced

ITEM REPLACE IF FOUND

Spark plug Electrode wear, insulator damage
Reed valve Damaged or deformed reed (Affects low rpm performance)
Clutch spring Fatigue
Drive sprocket Wear, crack, break
I Driven sprocket Wear, crack, break
Expansion chamber spring Fatigue, other damage
Exhaust silencer Noise level over permitted limit

6) TRANSMISSION OIL
Transmission oil capacity: 700 cc when refilling
800 cc when overhauled
Standard oil specification: 10W-4Q Motor

7) SPARK PLUG
Specification: NGK R5184 # 10 (STD); # 9=5 (Opt); # 10.5 (Opt)
Spark gap : 0,5 — 0,6 mm

8) SPARK PLUG CAP

From '89 model, the ignition system is digitally controlled. The digital control system is susceptible to
radio interference. Therefore, make sure to use the spark plug cap of standard specification.

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 KIT PARTS INSTALLATION PROCEDURES
This manual explains the installation, handling, setting and other important procedures for each component
of the kit parts. For more fundamental works not contained in this manual, refer to RGV250 Service
Manual.

1 . CYLINDER HEAD, CYLINDER, HEAD GASKET

0 The combustion chamber of kit cylinder head is
finished with a special plating so-called a BN
plating to prevent pitting in case of abnormal
detonation.
(D A thin cylinder head gasket (thickness = 0.7 mm)
is used for this kit to contribute to compression
increase. Also, the dimension of gasket bore is
made as close as possible to that of cylinder for
the purpose of decresing the quenching area,
thereby surpressing abnormal detonation to a
minimum.
(D The kit cylinder is different from the normal
one in its port timing, port shape and height of ^tp
cylinder.
® The dowel pins are used because of closer tole­
rance of cylinder head gasket bore off-center.
The dowel holes are provided on the cylinder,
cylinder head and gasket.
(5) To have the compression adjusted, a thinner
cylinder base gasket is used (thickness = 0.6 mm).

NOTE:
Exhaust timing of the kit cylinder is faster than is standard one. Therefore, if the standard exhaust
valve is installed without modification, the valve will protrude inside the exhaust port resulting in
decreased power.
Therefore, grind off the exhaust valve end so as to be flash with the exhaust port with the valve fully
opened.

Cylinder exhaust
port upper edge

Grind off

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 REF. NO. PART NUMBER DESCRIPTION QTY/UNIT REMARKS
1. 11111-12C60 HEAD, CYLINDER 2
2. 11141-12C50 GASKET, CYLINDER HEAD 2 t = 0.7
3. 11200-12C60 CYLINDER ASSY 2
4. 04211-11129 PIN, CYLINDER HEAD
4
KNOCK
5. 11241-12C50 GASKET, CYLINDER 2 t = 0.6

2 . PISTON AND PISTON RING

® A forged, light weight piston is used in this kit.
As with cylinder head combustion chamber, the
piston crown is finished with BN plating to pre­
vent pitting in case of abnormal detonation.
© A thin, 0.8 mm piston ring is used to decrease
weight and friction loss.
@The kit piston pin is light in weight yet highly
rigid due to its double tapered shape bore.
® & ® W i t h the change of piston pin, the circlip
and thrust washer are also modified.

NOTE:
When installing the piston, position its two
1,7 mm holes facing exhaust side.

[REF. NO. PART NUMBER DESCRIPTION Q'TY/UNIT REMARKS

1. 12110-12C53 PISTON COMP 2
2. 12140-12C51 RING SET, PISTON 2
3. 12151-12C50 PIN, PISTON 2
4. 12153-12C50 CIRCLIP, PISTON PIN 4
5. 12152-12C51 WASHER, PISTON PIN
4
BEARING

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 3 , CLOSE RATIO TRANSMISSION
Modify the gear ratios for better suitability for competition using the parts listed below. Refer to RGV250
Service Manual (99950-12070-01E) for details of replacement procedure.

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 |REF. NO. PART NUMBER DESCRIPTION Q'TY/UNIT REMARKS
1-1 24121-12C50 COUNTERSHAFT FOR WET CLUTCH
1-2 24121-12C60 COUNTERSHAFT FOR DRY CLUTCH
* 2 24221-12C60 GEAR, 2ND DRIVE NT: 17
* 3 24231-12C60 GEAR,3RD/4TH DRIVE NT: 18/25
* 4 24251-12C60 GEAR,5TH DRIVE NT: 27
5 24261-12C50 GEAR,6TH DRIVE NT: 25
6 24130-12C51 SHAFT, DRIVE
7 24311-12C52 GEAR, 1ST DRIVEN NT: 30
* 8 24321-12C60 GEAR, 2ND DRIVEN NT: 25
* 9 24331-12C60 GEAR, 3RD DRIVEN NT: 22
*10 24341-12C60 GEAR,4TH DRIVEN NT: 26
*11 24351-12C60 GEAR,5TH DRIVEN NT: 25
12 24361-12C50 GEAR,6TH DRIVEN NT: 21
*13 08211-25321 SHIM, 2ND DRIVEN GEAR
14 16320-12C50 GEAR, OIL PUMP DRIVE NT: 28
*15 24322-12C60 BUSH, 2ND DRIVEN GEAR

NOTE MARK *: NEWLY DEVELOPED.

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 4 . CLUTCH (FOR WET TYPE)
To reinforce the clutch for competition capability, replace the parts with those listed below. Refer to
RGV250 Service Manual (99950-12070-01E) for details of replacement procedure.

|^REF. NO. PART NUMBER DESCRIPTION QTY/UNIT REMARKS

1 21441-40A01 PLATE, CLUTCH DRIVE 8 T: 3 mm
2 21451-40A00 PLATE, CLUTCH DRIVEN 7 T: 1.6 mm
3 21471-12C50 SEAT, WAVE WASHER 1
4 09164-00006 WAVE WASHER 1
5 09440-19013 SPRING 6

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 5. CLUTCH (FOR DRY TYPE)

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 IREF. NO. PART NUMBER DESCRIPTION QTY/UNIT REMARKS
21000-12850 CLUTCH SET (DRY) INC..REF.N0.1'-33
1. 09282-58001 OILSEAL, INNER COVER 58 x 78 x 7
2. 21211-12C50 GEAR ASSY. PRIMARY
NT: 64/20
DRIVEN
3. 21251-12C50 SPACER, DRIVEN GEAR
4. 21252-12C50 SPACER, DRIVEN GEAR
5. 09263-25033 BEARING 2 5 x 3 0 x 19.8
6. 09280-20001 O-RING
7. 21220-12C50 HOUSING, CLUTCH
8. 09283-35023 OILSEAL 35 x 45 x 6
9. 21411-12C50 HUB, CLUTCH SLEEVE
10. 09160-20051 THRUST WASHER,
20 x 50 x 2
SLEEVE HUB
11. 21441-12C50 PLATE, CLUTCH DRIVE 5 T: 3 mm
12. 21451-20A01 PLATE, CLUTCH DRIVEN 6 T: 1.6 mm
13. 21471-12C60 SEAT, WAVE WASHER 1
14. 21472-12C50 WAVE WASHER,CLUTCH
1
SLEEVE HUB
15. 21462-12C51 DISC, CLUTCH PRESSURE 1
16. 21463-15400 BEARING, PRESSURE DISC 1
17. 09440-18017 SPRING, CLUTCH 5
18. 22522-12C50 SPACER, CLUTCH SPRING 5 6.5 x 13x25.6
19. 01107-06405 BOLT 5 6x40
20. 21481-17C50 WASHER 5 6.2 x 18.8 x 1.6
21. 23165-12C50 PACK,CLUTCH RELEASE
22. 23261-20A00 PINION, CLUTCH RELEASE
23. 08322-21068 WASHER, CLUTCH
RELEASE PINION
24. 23271-14101 ARM,CLUTCH RELEASE
25. 09135-06009 BOLT, PINION
26. 21111-12C50 GEAR, PRIMARY DRIVE

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 REF. NO. PART NUMBER DISCRIPTION Q'TY/UNIT REMARKS
27. 11341-12C50 COVER,CLUTCH INNER 1
28. 11370-12C50 COVER, CLUTCH OUTER 1
29. 11482-12C00 GASKET, CLUTCH COVER 1
30. 11342-12C50 PLUG, KICK SHAFT 1
31. 11971-12C50 PLUG, O I L F I L L E R 1
32. 07120-06252 BOLT 4 6x25
33. 11972-12C50 PLUG, OIL DRAIN 1
34. 24121-12C60 COUNTER SHAFT FOR
1 NT: 16 (Not shown)
DRY TYPE

6 . OIL CATCH TANK

1. Remove the under cowl.
2. Remove the front seat.
3. Remove the fuel tank.
4. Remove the air cleaner.
5. Install the oil catch tank on the chassis as shown in Fig. 2.
• Remove the front bolt securing the carburetor idle adjuster screw bracket. Refit this bolt to secure
the rear side of oil catch tank bracket together with the idle adjuster screw bracket.
• Pass the clamp (selt-locking tie strap) through the front bracket of oil catch tank and fasten the
clamp on the frame down tube. Use care at this time not to pinch the wiring harness between the
bracket and frame.
6. Remove the crankcase breather hose from the guide which is fastened together with the 1st muffler
mounting on the lower part of chassis right side. Route this breather hose to the oil catch tank as
shown in Fig. 1.
7. Insert one end of the outlet pipe (overall length 2 m) into the oil catch tank and route the pipe to the
rear of the machine. If the pipe is found too long, cut it to the proper length. When clamping the pipe
on the frame together with the wiring harness, use care not to pinch it.
8. Install the air cleaner.
9. Install the fuel tank.
10. Attach the self-adhesive clamp on the frame (tank rail) as shown in Fig. 1 and Fig. 2.
11. Replace the fuel tank breather hose with a longer one (length 790 mm).
• Insert one end of the fuel tank breather hose into the oil catch tank and secure the pipe on the
frame by using the clamp previously installed. If the pipe is found too long, cut it to the proper
length.
12. Install the seat and under cowl.
13. Finally, check that the steering does not interfere with the fuel tank breather hose when fully turned
right and left.

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 To fuel tank breather
(Fig. 1)
/
Length of hose
inserted

09352-50823-00B
HOSE, OIL CATCH TANK
OUTLET

To engine crankcase

VIEWC
Engine breather hose

09408-00074
CLAMP, FUEL TANK
BREATHER HOSE

To fuel tank breather

Oil catch tank bracket to be

tightened together with
carburetor idle adjuster screw
bracket using front side of bolt.

To crankcase

Secure front bracket on frame down tube by a clamp.

(At this time, do not pinch the side stand switch wiring
between the bracket and frame.)

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 7 . WATER CATCH TANK

To radiator conduction

Install the tank

with bands.

Water catch tank

Make a hole to catch water hose.

Air bleeding hole (3 mm dia.)

Water catch tank

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 8 . CARBURETOR SETTING PARTS
Set the carburetor in accodance with the conditions of the race course temperature, altitude (atmospheric
pressure), etc. Various types of setting are possible by various combinations of parts.

CARBURETOR TYPE

MIKUNI TM34SS, TWO

BORE SIZE, 34 mm

SETTING PARTS

M.J. P.W.J.

Leaner Leaner
#310 \
#320 ii

#330 #50
#340 #60
#350
#360 (IS)- T I
#370
#380 Richer
#390
#400
Richer

HJ. P.J.

Leaner
i
05 Leaner
06 4
07 #35
08 #37.5
09 #40
P-0 i
P-1 Richler
P-2 1

Richer

J.N. M.A.J. Richer

4
Leaner
CLIP POSITION i
#0.5
(#1.0) STD \r
1
1"t f

5th —'
ri A.S.
Leaner

Ric her
i

TURNING IN
1' I
V
1J Richer TURNING BAG K
Leaner

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 CARBURETION WITH DIFFERENT CLIMATIC CONDITIONS

Condition Result Required adjustment Parts to use

Cold Lean To make richer MJ or NJ
Hot Rich To make leaner it

Dry Lean To make richer a

Wet hot Rich To make leaner ii

High altitude Rich To make leaner a

CARBURETOR TUNING BY BIFFEREWT FAILURE SYMPTOM

SYMPTOM AJUSTMENT REMARKS

With full throttle;
• Rev peak too low
• Doesn't rev up quickly
• Poor power output (Rich)
• Decrease MJ size. • Check if choke is on.
• Decrease gradually by 1 — • Check if not overflowing.
2 sizes while observing
piston crown color.
© Decrease PWJ size.

With full throttle; ® Increase MJ size. • Check if air not leaking in.
1 • Hesitates « increase gradually by 1 — • Check if ignition timing not too
• Pings or knocks 2 sizes while observing fast.
• Revs up out power not piston crown color.
sufficient. • Increase PWJ size.

Performs dull or inter- Decrease NJ size to make (Rich at a partial opening)

j mittent in range 1/4 — 3/4 mixture leaner.
throttle opening.

Hesitates in range 1/4 — 3/4 Increase NJ size to make

throttle opening and torque mixture richer.
is poor.

Responds to gradual but not Decrease MJ size because of

to quick throttle opening. too rich main system.

Responce too sharp to Increase PJ size or lower JN

control position*

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 DESCRIPTION OF '89 RGV250 CARBURETOR TUNING

Throttle opening

0 15 25 35 50 75 100%

PJ >
^

y \
< NJ >

< MJ

< PWJ

This diagram indicates where each jet affects the carburetion throughout the throttle opening range.
• PJ (Pilot Jet): With 15% of throttle opening, carburetion is affected in entire revolution range and with
25% of throttle opening, in the range over 9,000 rpm.
• NJ (Needle Jet): With 15 — 25% of throttle opening, carburetion is affected in entire revolution range;
with 35 - 50% of opening, over 9,000 rpm; and with 75% of opening, over 11,000 rpm.
• MJ (Main Jet): With 75% of throttle opening, carburetion is affected in the revolution range over 9,000
rpm, and with 100% of throttle opening, in the range over 9,000 rpm,
• PWJ (Power Jet): With 75% of throttle opening, carburetion is affected in the revolution range over
10,000 rpm, and with 100% of throttle opening, in the range over 8,000 rpm.

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 CARBURETOR JETTING EXAMPLE (# 1 indicates the left cylinder and # 2 the right.)

FOR STAGE I
#1 #2 Atmospheric temperature: 10°C;
MJ #320 #320 Barometric pressure : 760mmHg.
For high speed circuit : Change with larger
NJ 0-9 0-9
MJ 2 - 3 sizes.
JN 6FL-76-52-3 6FL-76-52-3 Change with larger
PJ 35 35 NJ by 1 - 2 sizes.
MAJ 0.5 0.5
PWJ 60 60
AS 1% Turns back 1% Turns back

FOR STAGE H
#1 #2 Atmospheric temperature: 10°C;
MJ #340 #350 Barometric pressure : 755 mmHg
For high speed circuit Change with larger
NJ P-1 P-1
MJ 2 - 3 sizes.
JN 6FL-76-52-3 6FL-76-52-3 Change with larger
PJ 35 35 NJ by 1 size.
MAJ 0.5 0.5
PWJ 60 60
| AS 1% Turns back 1% Turns back

If aviation gasoline is mixed, the jetting may

be altered from the above charts as indicated
below:

With 50% of mixture If with MJ, smaller by 1 size

100% avgas If with MJ, smaller by 2 sizes

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 CARBURETOR DISASSEMBLY
• Replacing main jet and needle jet
Loosen the four screws and remove the float cham­
ber from the carburetor body. Remove the main jet
@, and then needle jet ®, Replace them with the
jets of other number required.

MAIN JET NEEDLE JET

#310 09491-62005
#320 09491-64002
#330 09491-66002
#340 09491-68002
#350 09491-70011
#360 09491-72011
#370 09491-74003
#380 09491-76003
#390 09491-78001
#400 09491-80010
0-5 09494-00653
0-6 09494-00612
0-7 09494-00613
0-8 09494-00614
0-9 09494-00615
P-0 09494-00668
P-1 09494-00663
P-2 09494-00664

® Replacing pilot jet

Replace the pilot jet © with the other number
required.

PI LOT JET
#35 09492-35004
#37.5 09492-35006
#40 09492-40004

® Replacing power jet

Check the power jet © number and if necessary,
replace with the jet of suitable number.

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 • Adjusting jet needle position
Remove the carburetor top cover by loosening two
attaching screws. Remove the jet needle @ from
the throttle valve ©* Check the current clip posi­
tion and change it to a position required.

Needle clip

JET NEEDLE
6FL76-52 13383-12C60

® Replacing main air jet

Check the current main air jet size and replace with
the size required.

MAIN AIR JET

# 0 . 5 09493-50004

• Blinding air valve

The standard model is equipped with the air/fuel ratio control system which operates according to the
engine rpm. This system includes an auxiliary main air passage which opens through the air valve as the
engine requires. While this system is effective on highways, it is no longer required in the competition use
where high revolutions are maintained most of the time. Therefore, modify this system as follows: Remove
the air valve. Blind the air passage by cutting the tube near the carburetor and inserting the plug (04221-
04069) into the tube end with liquid gasket applied. Secure the plug with wire as illustrated.

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 MODIFYING AIR CLEANER BOX
Along with the carburetor setting modification, the air cleaner box should also be modified as shown
below.

• Air cleaner cap modification

Cut the air cleaner cap in half.

30 mm
Cut at 30 mm from the hook.

NOTE:
The net and filter element inside the air cleaner box are no longer used.

• Air cleaner box modification

Cut off both the sides of the box in the same shape as the space formed between the tank and frame as
illustrated.

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 Cut the box further as illustrated here.

Cut the wall separating

# 1 and # 2 at 50 mm
from the rear end.

an opening in the rearmost

the box t o take air f r o m the
duct.

Connect the air duct to the air cleaner box as illustrated.

T o prevent loss of air in this

area, seal the top w i t h a cloth
tape.

To guide air supplied f r o m the

air duct into the box, wrap this
space w i t h a piece of rubber
sheet and fasten it to the box
using tie straps.

Tie strap

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 9 . MUFFLER REPLACEMENT
1) Remove the under cowl.
2) Remove the # 1 muffler.
3) Remove the # 2 muffler. Spring
4) Replace the exhaust gasket with new one.
2nd muffler

Exhaust gasket ^

Exhaust flange \

Wire lock

Spring

5) Install the exhaust flange on the # 2 side 1st muffler.

6) Mount the muffler on the engine and chassis in proper position*
7) Secure the 1st muffler on the exhaust flange using two springs.
8) Position the 2nd muffler on the 1st muffler properly referring to the tail pipe direction and hook the
two springs.
9) Assemble the # 1 side muffler in the same manner as above,
10) Secure the connection between the 1st and 2nd mufflers using a wire as illustrated.
11) Remove the pillion footrests and their brackets as they are not necessary for installing the muffler of
this kit.
12) To prevent the spring from breaking due to vibration, put a piece of rubber tube such as fuel hose over
the spring as illustrated.

■22'

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 1 0 . OIL PUMP REMOVAL AND BLINDING
As fuel/oil mixture is used, the oil pump and oil tank are no longer needed. Modify the system according
to the following procedures:
1) Remove the oil tank.
2) Drain transmission oil.
3) Remove the magneto cover.
4) Remove the oil pump inspection cap.
5) Remove the oil pump assembly carefully so that the gasket will not be damaged.
6) Remove the oil hoses extending to cylinder and crankcase as they are no longer used.
7) Install the oil pump cap (16432-12C50) in the position from which the oil pump has been removed
using the screws (02112-35168).
8) Cut the oil hose removed from the system to make a short hose, bling one end as shown in the illustra-
tion and attach it to each of the oil check valves for the cylinder and crankcase.

Bend and tie with a wire.

Check valve

9) Remove the oil pump cable and throttle No. 5 actuator cable as they are no longer used in the system.

Remove the fuel tank. Remove the air cleaner

case. Detach the cable box case ® from the
chassis and remove its cap (2).

'r
Remove the oil pump cable d ) .

\
Remove the actuator cable ® .

i
f

Remove the throttle sensor (5).

-23-

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 B§tftlf

/ .1 ^.'i^W

~24~»

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 1 1 . SPROCKET REPLACEMENT
Lock nut Rear sprocket
REPLACING REAR SPROCKET /
To remove the rear sprocket, first remove the rear
axle, then take off the entire rear wheel Remove
six rear sprocket nuts from the wheel
Tightening torque:
Rear sprocket nut
10 mm: 40 - 60 N°rrt (4.0 - 6,0 kg-m)

ear wheel

REPLACING ENGINE SPROCKET

• Remove the under c o w l
Engine sprocket
• Remove the gearshift link arm bolt and detach
Circlip
the gearshift link arm from the gearshift shaft.
• Remove the sprocket cover by loosening four
attaching bolts.
• Remove the circlip from the shaft and pull out
the sprocket.
• Replace the sprocket with one provided in this Rounded edge
kit. should face
the engine
(inside)
NOTE:
When installing the sprocket and circlip, make
sure they are positioned correctly as shown in CIRCLIP INSTALLATION
the illustration.
Installing direction
of circlip
NOTE:
Engine sprockets of 13 — 16 teeth and rear
sprockets of 37 — 45 teeth are optionally
available. Select the most suitable number
according to your local race track condition. Round edge side

ADJUSTING DRIVE CHAIN

Adjust the drive chain so that the sag is between
15 — 25 mm when measured at the mid point be­
tween the two sprockets. To adjust, loosen the axle
shaft ® and turn the chain adjuster© . M^

The chain adjustment should be made while

also adjusting the wheel alignment.

Tightening torque:
Rear axle nut: 55 - 88 Mm (5.5 - 8.8 kg-m)
Chain adjuster lock nut: 1 0 - 1 6 N-m
( 1 . 0 - 1.6 kg-m)

•25-

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 1 2 . REAR SUSPENSION
HEIGHT ADJUSTER
BRACKET INSTALLATION
1)Remove the existing bracket in the following
procedure.
• Remove the fuel tank, seat and side covers.
• Remove the rear shock absorber upper nut ® .
• Remove the rear shock absorber lower nut © *
• Remove the rear shock absorber assembly @.
• Remove the existing bracket @ by loosening
the b o l t s ® .

2) Installation
® Bracket, rear shock 41762-1 2C50
© C l a m p , rear shock bracket 41763-12C50
© Nut, rear shock bracket 09159-14015

• Assemble the b r a c k e t ® , clamp © a n d nut © o f

the kit as shown in the illustration.
• On the frame, install the bracket® assembled in
the above procedure using the bolts (£).

50 - 80 N-m 1
<D (5.0 - 8.0 kg-m)
Tightening torque
1 8 - 2 8 N-m
®
( 1 . 8 - 2 . 8 kg-m) |

Standard adjuster
£ = 40 mm
position

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 1 3 . PROMT FORK
• Constructed with inner rod
• Damping force adjustable both for compression
and rebound dampers.

DESCRIPTION OF FORK OPERATION

Rebound damper
• When the fork extends, oil in the oil chamber
(B) is forced away through the rebound damping
valve 0 . A t the same time, oil goes up through ^
the inner rod (2) and then the adjuster©. Also / L \3l
oil in the chamber @ is transferred to the cham HrffTO—©
ber © . The damping adjuster @ and rebound j f||
damper valve 0 contribute to damping force.

Compression damper
• When the fork is being contracted, oil in
the oil chamber © is forced away through
ft 1 J|fl J -

_J^_^_^_^»_^__^JL.
Inner tube

the relief valve 0 , compression damping

valve © and adjuster @ . Among these j ig§^"
passages, the damping adjuster © a n d com­ IraJl
pression damper valve © contribute to
Jill liil
damping force.
©1 Mil (o)

K i 4¥¥—"""""" l n n e r tu
^e
i l l Hn—®
1
§3pr

C®_SJwll
BH—®

M
bi
\1]|
L-©
4_ tJJIJ-j—©
"">® (Q)" [it
MB

y~w
fn\ M
^^5n^ ^
r\ i |j
®~~mm A

mtk

-27-

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FROM! K>Rk DISASSEMBLY
Loosen the inner tube cap ® and lower the inner
tube®*
Remove the inner tube cap.
Remove the spring retainer © . Then, remove the
s p a c e r ® , w a s h e r ® and spring ® .
Remove the dust seal @.
Detach the spring stopper @.
Loosen the inner tube bolt @ using the special
I tool.
Special t o o l : 09940-31710 I
Front fork assembling tool
I Remove the inner rod assembly.

Disassemble the spring adjuster in the following

Slide out the inner tube, remove the oil seal @
prodecures:
and slide metah
© Remove the spring adjuster © .
® Remove the spring (8) and ball © .
Remove the compression damping adjuster @ .
© Remove the damping force a d j u s t e r © .

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 EXPLODED VIEW

® Adjuster Spring washer

(D O-ring Spring spacer
(D Ball, spring Spring retainer
(4) Oil lock piece Spring adjuster
(5) Inner tube Adjuster
(6) Piston O-ring
(7) Outer tube Ball
(D Slide metal Spring
(9) Washer Lock nut
© Oil seal Inner tube cap
(Q) Stopper ring
@ Dust seal
@ Inner rod
©Bolt
© Spring

-29-

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 REPLACING FRONT FORK PARTS
• Fit the O-ring © , ball and spring © t o the com­
pression damping adjuster ® .

NOTE:
Locate the spring so that its end gap comes
opposite to the bail.

• install the compression damping adjuster® sub-

assembly.

Tightening torque:
Compression damping: 150 - 200 N*m
adjuster (15.0 - 20,0 kg-m)

• Install the oil lock piece ® t o the outer t u b e ® .

• Insert the inner tube © with the piston ©
fitted, into the outer t u b e ® .
® Fit the slide metal © , washer © and oil seal ©
over the inner tube and the into the outer tube
bore. Use the special tool to fit them together
into the outer tube.

Specie! tool:
09940-50112: Oil sea! installer

NOTE:
The pjirten © , slide metal © and oil seal ©
myst be replaced with new ones.

© F i t the stopper ring (JJ) and dust seal ®.

MOTE
Make sure that the stopper ring is correctly
fitted into the graowe.

• Install the inner rod assembly ® .

• Fit and tighten the inner tube cylinder b o l t ® .
This time, use the special tool to hold the inner
rod,

Special tool:
09940-31710: Front fork assembling tool

Tightening torque:
Inner tube cylinder bolt: 300 — 40 N*m
( 3 0 . 0 - 4 0 . 0 kg^m)

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 • Insert the spring © , washer © , spacer @ and
retainer© into the inner tube.

NOTE:
The smaller coil diameter side should face
downward when installed.

Assemble the spring adjuster © in the following

procedyres:
Install the adjuster®.
Fit the O-ring©,
Fit the ball @ and spring© .

NOTE:
Locate the spring so that its end gap comes
opposite to the ball. Also, use care so that the
spring will not be distorted.

• Turn the lock nut ® all the way in lightly.

• Have the adjuster © protruded by 1.5 mm.
• Turn the spring adjuster © all the way in lightly.
• Hold the spring adjuster @ securely and tighten
lock n u t ® . »
I ,5mm

Tightening torque
Lock nut: 175 - 225 N-m (17.5 - 22B5 kg-m) ~f IF*.

• Install the inner tube cap© . -®

Tightening torque
^ s ^ - — -®
Inner tube cap: 1 5 0 - 3 0 0 N°m (15.0-30 o 0kg-m)

• Return the adjuster @) to the standard position.

Set the spring adjuster

position to the 4th line
counted from top.

Stopper

-31 -

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 ADJUSTMENT
Spring preload adjustment
• Turn the spring adjuster and check the preload
reference lines provided on the adjuster circum­ Spiing adjuster.
ference.
• The preload can be adjusted in seven different
settings:

Turning clockwise: increases the preload.

Turning counterclockwise: decreases the pre­
load.

Standard setting 4th line from the top

/
Damping force adjustment Damping force^
• This adjustment procedure is applicable to the adjustmc-m.
(rebounJ)
optional fork as explained above.
• In this fork, both the compression damping and
rebound damping can be individually adjusted.
• The compression damping adjuster locates on
the top end of fork tube and rebound damping
adjuster locates on the bottom part of the fork
Rebound Compression
tube as shown.

Standard setting
Rebound:
Turn the adjuster clockwise all the way in. Slowly back it until you feel a first click stop (this click is
counted as # 0). Then, turn back the adjuster further until # 4 click stop is reached.
Compression:
Turn the adjuster clockwise all the way in. Slowly back it until you feel a first click stop (this click
is counted as # 0). Then, turn back the adjuster further until # 3 click stop is reached.

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 FRONT FORK SPRING
• Select either of the two springs provided in the
kit.

Part No. Characteristic Identification notch

5117M2C50 Softer 1
5117M2C60 Stiffer 2 J
NOTE:
The identification notch locates on the end
of the spring as shown in the illustration.

Check the oil level of front fork when compressed

fully and adjust it to the specification.

Standard oil level

Front fork oil

n
Oil level (measured level guage
Part No. (09943-74111)
from inner tube top end)
I 5117M2C50 100 mm I
5117M2C60 108 mm

CAUTION:
The adjustment should be made so that both the right and left damping (whether compression or re­
bound) are set in the same position.

-33-

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 1 4 . REAR SHOCK ABSORBER SPRING REPLACEMENT
• The rear shock absorber is equipped with a
separate oil reservoir.
• The damping force can be adjusted for both the
compression and rebound dampers.

Reservoir tank

0 Rear shock absorber

(2) Reservoir tank cushion
(D Clamp
® Clamp L: 125 Rear shock
(5) Bolt 1 0 x 5 8 absorber

1) REMOVAL
• Referring to the removal procedure of rear
suspension height adjuster bracket installation
previously explained, remove the shock absorber
assembly.
• Slide the stopper rubber © upward.
• Compress the spring (2) and remove the spacer (§)
then spring guide ® .
• Remove the spring from the shock absorber
body.
® Select either of the two springs provided in this
kit.

[ Part No. Characteristic Identification notch

62211-12C60 Softer Red
[62211-12C50 Stiffer Yellow

2) ASSEMBLY
Take the reverse sequence of the removaI procedure.

NOTE:
The spring must be installed with its smaller coil diameter side facing the spring adjuster (upward).

-34-

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 3) ADJUSTMENT

Rear shock absorber spring adjustment

Adjusting range
• To adjust the spring preload, turn the retainer 5 mm U*| 5mm Lock nut
after loosening the retainer lock nut. Retainer

Adjusting range : 17 — 25 mm -A
Standard position: 22 mm

The dimension indicates the lock nut upper face

positions as measured from the reference position.

Standard position
NOTE:
Do not adjust the spring beyond the adjusting
range.

Damping force adjustment Rebound Compression

• This adjustment is based on the machine equip­
ped with the optional variable damping force
type shock absorber.
• In this absorber, both the compression damping
and rebound damping can be individually ad­
justed.
• The compression damping adjuster locates on
the oil reservoir and rebound damping adjuster
locates on the bottom part of the absorber as
shown.

Standard setting
Rebound:
Turn the adjuster dial referring to the number shown on its circumference. Number 2 position is the
standard setting.
Compression:
Turn th.3 adjuster dial clockwise all the way in. Slowly back it until you feel a first click stop (this
click is counted as # 0). Then, turn back the adjuster dial further until # 10 click stop is reached.

-35-

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 1 5 . FRONT BRAKE CALIPER
PAD MODIFICATION
• Loosen caliper mounting bolts 0 f r o m the front
fork and remove the brake caliper assembly.

• Remove the pad cover 0 .

® Remove the brake pads.

• Insert the kit insulators © a n d ® , two each, into

the piston recesses as shown in the illustration.
\
INSULATOR ©4
Part No. Characteristic
®
®4 r.—i,
59109-12C50 Small diameter
i—P*" \ \ \
\®_ 59109-19C00 Large diameter

\
v» 1 1 — */
Piston

Replace the brake pads with ones provided in

the kit.

Part No. 59100-12850

NOTE: NOTE:
If the kit brake pad is used, the insulator When using the pad (59130-12C60) f use of
should also be used together. the insulator is not necessary.

-36

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 1 6 . STEERING DAMPER INSTALLATION
1) KIT CONTENTS
The steering damper kit consists of the following parts.

©Bolt 6 x 3 0
© B o l t 6 x 10

Lock washer

) Lock washer — - { @ )

) Nut 6 mm —ClF^fl ® Rod end

I REF. NO. PART NUMBER DESCRIPTION QTY/UNIT I

® 51781-12C50 BRACKET, STEERING DAMPER 1 1

© 07110-06307 BOLT, BRACKET FORK CLAMP 1
© 09164-06009 WASHER, BRACKET STEERING DAMPER 4
© 07110-06307 BOLT 1
© 09180-06092 SPACER 1
© 51721-15400 BEARING, ROD END STEERING 1
I © 08310-11087 NUT 1
© 08310-11067 NUT 1
© 51750-12C50 DAMPER ASSY, STEERING 1
© 51791-15400 BRACKET, STEERING DAMPER 1
© 07110-06257 BOLT 1
© 07110-08407 BOLT 1
© 09180-08067 SPACER 1
® 51723-12C50 STOPPER, STEERING 2
© 07110-06108 BOLT, STEERING STOPPER 2
© 51795-15400 PILLOW BALL, STEERING DAMPER 1
I © 41684-12C50 BRACKET, STEERING DAMPER 1
^37-

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 2} INSTALLATION
Assembling the kit components
• Attach the rod end ® and nut © onto the steering damper ® B
Tightening torque: 10 - 16 N°m (1.0 - 1.6 kg-m)
• Mount the bracket © o v e r the steering damper®, attach bolt ©together with lock washer® and screw
the bolt to bring it to finger tight.
• Attach the bolt © together with lock washer ® onto the bracket ® and bring the bolt to finger tight.
• Connect the rod end ® t o the bracket® using bolt (4), lock washer ® , spacer ® a n d nut ® a s shown in
the illustration. Tighten the nut ® to specification.
Tightening torque: 4 — 7 N®m (0.4 - 0.7 kg-m)

Mounting steering damper

® Loosen the fork inner tube clamp bolt ® .
• Remove the handlebar clamp bolt (§).
• Remove the steering upper bracket nut ® -
• Remove the steering upper bracket.
• Remove the left handlebar holder from the fork
inner tube8
• Slide the bracket ® of the steering damper sub-
assembly (as explained above) over the fork
inner tube.
• Mount the bracket © of the damper subassemb-
ly onto the tapped boss provided on the frame
using bolt © and spacer (Q).
Tightening torque: 10 — 16 N-m
( 1 . 0 - 1 . 6 kg-m)
• Remount the left handlebar holder on the fork
inner tube.
• Remount the steering upper bracket.
• Tighten the steering upper bracket nut © to
specification.
Tightening torque: 60—100 N-m
( 6 . 0 - 10.0 kg-m)
• Tighten the handlebar clamp bolts ® to specifi­
cation.
Tightening torque: 15 — 25 N-m
(1.5 - 2 . 5 kg-m)
• Tighten the fork inner tube bolts ® to specifi­
cation.
Tightening torque: 15 — 25 N-m
( 1 . 5 - 2 . 5 kg-m)

-38-

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 Steering damper setting
• Move the steering damper forward or backward through the bracket @and locate it so that the damper
rod travels forward and backward in an equal distance when the steering is turned to the right and to
the left from the center position.
• When the proper location is obtained, tighten the bolts (2) and © to the following torque specification
Tightening torque: (2) Bolt 4 — 7 N°m (0.4 - 0.7 kg-m)
© Bolt 4 » 7 N - m (0.4 - 0.7 kg-m)

CAUTION:
It is extremely important that the bolt ® be torqued to the correct specification. After completing
the adjustment, make sure that the steering turns smoothly both to the right and left.

Mount the steering stopper ® on the stopper

boss ® formed on the steering lower bracket
® and tighten it with the bolt © .
® Lower bracket
Tightening torque: 4 — 7 N°m (0.4 — 0.7 kg-m)

3) IMPORTANT NOTICE
• When using the steering damper, also use the
steering stopper as above. Some race regulations
prohibit the use of steering damper in such way ) Stoppe
as to cause it also work for steering stopper. boss
• This steering damper is equipped with damping
adjuster. The adjustment can be made in 17
different settings (by turning the dial).

f**"—
n,
__£~1 1—n
• , i I
- Make a shallow spot-face
w p? on the stopper boss for
secure bolt end seating.

v_

-39-

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 1 7 . SUSPENSION SETTING
For rider weighing 60 kg

l ^ ^ ^ ^ ^ ^ VERSION
STANDARD STAGE I KIT STAGE II KIT
ITEM ^ ^ ^ - ^ ^
Spring adjuster (Initial) # 4 line from top # 5.5 line from top # 4 line from top
Damp­ Rebound 4 clicks back 1 click back 3 clicks back
ing Compression 3 clicks back 4 click back 9 clicks back
Inner tube top protrusion 10 mm 15 mm 23 mm
F
R Spring constant 0.55 kg/mm <- «-
o Oil level 103.7 mm 103.7 mm 95 mm
N
T Fork oil Showa SS8 ^_
*"
Sag with one rider 54 mm (-8) 43 mm (-8) 42 - 45 mm (-8)
Other spring constand ® 0.5 kg/mm
(Optional) © 0.6 kg/mm
Spring initial setting 179 mm -*- <-
Spring constant 7.0 kg/mm 6.0 kg/mm 6.0 kg/mm
Damp­ Rebound 2nd position 2nd position 4th position
R ing
E Compression 10 clicks back 5 clicks back 12 clicks back
A Sag with one rider 35 mm 24 mm 7 — 9 mm
R

Height adjusting range 5 = 31 mm (see P26) I

Other spring constant ® 5,0 kg/mm 6.5 kg/mm provided last year
(Optional) © 6.0 kg/mm not available from '89 model.

^40-

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 1 8 . SUSPENSION SETTING GUIDE
—
f 1. Unsmooth sliding -
r • Check suspension sliding parts.
• Check for front axle off-center or twisted fork.

-2. Spring preload too • Decrease spring preload.

high • Change with spring with lower spring constant.
• Decrease oi I... 1 cc= 1mm; Decrease 5 cc at a time.

FEELS ROUGH ■3. Bottoming • I ncrease spring preload.

• Change with spring with higher spring constant.
• Increase oil.

4. Damping too much • Decrease damping force.

5. Tire too hard • Review tire selection. Decrease pressure.

FEELS TOO SOFT Damping not enough • Increase damping force.

UNDERSTEERS Caster too much • Increase inner tube top end protrusion.
• Decrease front fork spring preload load.
• Increase rear spring preload.
• Decrease rear rebound damping force.
• Raise chassis rear end.

- 1 . Rattles in steering
head pipe • Check tighteness of bearing and nut.

-2. Tire or wheel im

CHATTERS-> balanced or deformed • Correct balance. Check deformation.
(Small pitching)
-3. Tire not matched
• Review tire selection. Try different air pressure.
■ 4. Chassis not matched
t • Avoid resonance by changing spring preload,
• or by changing damping force.
■1. If occurs when power on.
Insufficient fork .— • Decrease spring preload.
KICKS BACK ->
rebound travel I— • Increase front weight distribution. (Increase fork
(Steering shaking)
inner tube top protrusion. I ncrease rear end height.)

-2. If occurs when power

off.
Insufficient fork com­
pression travel u Decrease front spring preload.
Decrease spring constant.

Too much fork com- -

pression travel t Increase front spring preload.
Increase spring constant.

-41 -

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 1 9 . STAGE I KET PARTS ELECTRICAL
When assembling the Stage I kit, make sure that all the following parts are used together in the electrical
system. With the kit control unit used in the system, the characteristics of ignition advance and exhaust
timing control system are automatically changed to the specifications suited for competition use.

IREF. NO. PARTNAMBER DESCRIPTION QTY/UNIT REMARKS

1. 36610-12C80 HARNESS WIRING (SP) 1 '89
2. 32910-12C80 CONTROL UNIT (SP) 1 '89
3. 37250-38200 SWITCH ASSY. KILL 1
4. 32157-12C00 CLAMP, PULSER COiL(SP) 1
5. 07110-05128 SCREW, PULSER COIL (SP) 2

With the kit installed, the air valve and throttle sensor are no longer necessary for competition and there­
fore remove them from the machine.

Switch assy, engine stop Wiring harness

P I ® Meter

^*C>(2) Switch assy, engine stop

Switch assy, engine stop
(D Water temp, gauge

■® No. 1 coil (3) Water temp, gauge

© N o 2 coil ® No, 1 coil

® No. 2 coil

k^k © Battery ©

(Q) Battery ©
Dl——(9) Ex control unit
J) Magneto
@Fuse

© Ex control
unit
Battery ©
(D Regulator

Regulator

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 • The illustration below shows the installation of magneto pulser coil clamps (32157-12C00).
• The clamps are installed to surpress vibration which otherwise increases and interferes with the pulse
signals due to increased power and revolutions of the kit installed engine.

43

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 2 0 . STAGE II KIT PARTS ELECTRICAL
The Stage II kit includes a GDI ignition system that does not utilize battery current. The rotor is of light
weight construction to decrease moment of inertia, resulting in quicker revolution pick up. The ignition
advance and exhaust timing control characteristics are also modified with the kit to be suited for Stage n.

1REF.NO. PART NUMBER DESCRIPTION Q'TYUNIT REMARKS

94510-12C51 BRACE COMPCOWLINK 1 Can be used for Stage I.
^
2. 32900-12C70 GDI UNIT 1
3. 02112-16206 SCREW CDI UNIT 2
4. 34161-12C50 HOLDER TACHOMETER 1 Can be used for Stage I.
5. 09123-06023 SCREW HOLDER TACHO 3 //
6. 09160-06028 WASHER HOLDER TACHO 3 11

7. 09180-06040 SPACER HOLDER TACHO 3 ••

8. 08319-21068 NUT HOLDER TACHO 3 II

9. 32100-12C70 MAGNETO ASSY 1

10. 32374-12C50 BOLT MAGNETO PLATE 2
11. 02122-05128 SCREW MAGNETO 3
12. 36610-12C50 HARNESS WIRING 1

-44-

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 (y) Apply NEJI-LOCK (Three Bond 1322)

Meter
Temperature gauge
, _ A ^ m GDI unit
Q/\M Kill switch
B/G ' Or

:, d1
No. 1 coil
B/Y
I B/G£j Temperature gauge

©-
W/BI
No. 2 coil DT

Magneto

-45-

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 MEMO

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 MEMO

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 Prepared by
SUZUKI MOTOR CO.fLTD,

Sales Department II (for overseas)

Spare Parts & Accessories Division

August, 1989
Part No. 99000-69445

Printed in Japan
V J

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 SUZUKI MOTOR CO LTD

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