ete GN2Se SERVICE MANU 4. ‘ S = bsFOREWORD The SUZUKI GN250 was designed to offer superior performance through design, four stroke power (TSCC engine). The new GN250 represents anather r vance by Suzuki in four stroke motorcycles. This service manual has been produced primarily for experienced mechani to inspect, adjust, repair and service Suzwki Motorcycles. Apprentice mech. it yourself’ mechanics will also find this manual to be an extremely useful guide, Model GN250 manufactured to standard specifications is the main subjeet matter of this manual. However, the GN250 machines distributed in your country might differ in minar respects from the standard-specification GN250 and, if they do, it is becatise some minor modifications (which are of no consequence in most cases as far as servicing is concerne had to be made to comply with the statutory requirements of your country This manual contains up-to-date information at the time of it cations and changes will be explained to each SUZUK/ distribut to whom you are requested to make query about updated information SUZUKI MOTOR CO.,LTD. Service Publications Department Overseas Service Division Quating, copying or otherwise using any part of this manual without ex- plicit-authorization from Suzuki Motor Co., Ltd. is not permitted as all rights to the publication are reserved under copyright law.VIEW OF SUZUKI GN250 (DISC AND CAST TYPE) LEFT SIDERIGHT SIDE LEFT SIDEVIEW OF SUZUKI GN250 (DRUM AND SPOKE TYPE) RIGHT SIDE LEFT SIDEGROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE AND ___TUNE-UP PROCEDURES __ SERVICING ENGINE FUEL AND LUBRICATION SYSTEM ELECTRICAL SYSTEM CHASSIS SERVICING INFORMATION GN250D (’83 MODEL)GENERAL INFORMATION —_— CONTENTS — ei | VIN AND SERIAL NUMBER LOCATIONS «+: ++++-++--200rerreeeeeree eee 1-7 | FUEL AND OIL RECOMMENDATIONS ---:--0:00ccsceeceeetreeeeeteee te 1 | BREAK-IN PROCEDURE «++ ::r1rressteercecrestecsseesevescsscsnepacseseseeefn J SPECIAL RRATURES 2c: ease) scabs af heagtente ceecesereereemeaeiee iteeaheye SPECTAL EATER AS ste ont oar totes ee yan nena ore yee eee 1-10 | PRECAUTIONS AND GENERAL INSTRUCTIONS. 1-12 GPECIEICATIONS i :-:scseos coi a pan ennaestaet eet mere eee ad |VIN AND SERIAL NUMBER LOCATIONS The VIN number UW 15 stamped on the steering head pipe. The engine serial number (2) is located on the crankease. These numbers are required especially for register- ing the machine and ordering spare parts. FUEL AND OIL RECOMMENDATIONS FUEL Gasoline usec shold be graded 95-95 octane or higher. An unleaded oF low-lead type gasoline ts recommended ENGINE OIL Be sure that the engine oi! you use comes under API classification of SE or SF and that its viscosity rating is SAE 10W-40. If SAE 10W-40 motor oil is not available, select the oil viscosity according to the following chart: SAE = 40 30 | =z 20W/50 1OW/50 10W/30 ee | 20 | =e [ Tow =a cl =a—10 0 qo 20 40 40 Temp. Fp} 3 ia 32 50 68 86 104 FRONT FORK OIL | FORK GIL #10 | BREAK-IN PROCEDURE During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subject- ing the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life, The general rules are as follows: e Keep to these breaking-in engine speed limits: initial 80Okm | Belaw 4,500 r/min Up to 1,600 km |. Below 5,500 r/min Over 1,600 km Below 9,500 r/min {_ = « Upon reaching an odometer reading of 1,600 km you can subject the motorcycle to full throttle operation. However, do not exceed 8,500 r/minatany time. e@ Do not maintain constant engine speed for an extended time period during any portion of the break-in. Try to vary the throttle position.~ GENERAL INFORMATION 1-2 —_— eee ae SPECIAL FEATURES TRANSISTORIZED IGNITION SYSTEM WITH ELECTRONIC ADVANCE On the Model GN250, the timing advance characteristics of the ignition timing have been changed fram the hitherto-employed mechanical timing advance system incarporating an advanee governor ta an electronic timing advance system. This system consists of Magneto tip, pick-up coil, ignitar and ignition coil as shown in Fig. | Ignition switch oon = Pick up L “ Spark plug coil Battery O/W ee Igniter 3 Ly — Magnete Se aw — - TH Fig. 1 When the Magneto tip is rotated in the system block diagram above, the signal ‘’A" is generated in the pick- up coil. The this-generated signal will be converted to the signal waveform ‘'B inside of the ignitor unit and ignition timing is controlled in response to the engine speed as shown in Fig. 2. That is, timing controlled in the ignitor unit becomes j, when the engine speed is lower than Ni ,and it becomes the engine speed is; ~ N>, The advanced angle when ignited with (2) is a) 2 when » When higher than N: , timing is), and the timing does not advance higher than the above, The maximum advanced angle is a6o° Fick-up coil signal Engine start-speed revolution \/ Engines \below Nr slow-speed revolution Medium-speed » Between revolution Vy and Mi! High-speed ; { Over Na } revolution = 1700 r/min me DP Fig, 2 v2 SaThe quick completion of burning results in more energy being developed while the piston is in position to transmit maximum power to the crankshaft. High burning efficiency results in more power, improved throttle response at all rpm's, more complete combustion of the air/fuel mixture (cleaner combustion) and less chance of detonation. Second, charging efficiency. @ benefits of increased burning efficiency are further multiplied if imtake d. Basically, increasing the charging efficiency results in more fuel and air charging efficiency is also increas being drawn into the engine during each intake stroke. Thus, greater anergy potential. Toe achieve this, the four valve head was adopted. Two smaller diar r intake valve can flow more than one large valve. Additionally, two smaller valves run cooler due to increased valve seat area and two valve guides to increase heat transfer, SQUISH HEIGHT (A) : Wall (B) : Wall | PISTON SQUISH AREA 7 : (B) TSCC PROFILE PLUG HOLE {Al / CYLINDER BORE PROFILE “JAPAN PATENT No, 771502AAL INFORMAT But SUZUIK| went one step further. The valves are set in at a much shallower angle than other engines. The result is a smoother intake tract with less valve guide protrusion than in conventional cylinderheads. Therefore, increased flow, and smoother, less turbulant flaw which contributes to more power and improved throttle response at all engine speeds. There are several other benefits, This design is more efficient and will flow more air/fuel mixture than a conventional 4-valve head. Therefore, even smaller, lighter valves can be usec) with no decrease in power, Also, the valves can be shorter due to the placement angle, This allows more precise valve control since shorter, lighter valves are more easily controlled-especially at higher ram's. Yet another benefit of valves set at shallower angles is that the volume of the cylinder head combustion area is decreased. This allows the use of racing type flat-topped pistons since the desired compression ratio can be achieved without resorting to domed pistons. Flat topped pistons offer no restriction to the in- coming air/fuel mixture and a flat-topped piston exposes the minimum amount of surface area to the hot burning mixture. This means that the flat piston absorbs less heat and therefore has to dissipate less heat through the rings and ta the ail than a conventional domed piston, The result isa cooler running engine, Flattopped pistons can algo be made lighter resulting in less vibration and stress. Increases burning efficiency. Increased charging efficiency, The result is more power throughout, from idle to redline. Throttle response is instant and clean, Displacement for displacement, no conventional engine, 2-valve or 4-valve, can compare. This could be enough, but SUZUK! went even further to ensure reliability and ease of maintenance, Each rocker arm,when depressed by the cam lobe activates two valves at one time. With this system, engine performance is increased and tappets are not necessary, This system allows the use of larger valve springs which increases spring life by reducing stress, Valve adjustment is accomplished quickly and easily. The patented TSCC combustion system combined with SUZUKI's high efficiency charging design results in power and throttle response found only in this new generation 4-stroke engine.GENERAL INFORMATION TSCC valve angle a is smaller than ff, (A) is the same, spring 3) is larger thar | Tscc valve angle TSCc La. "] 4yalve Conventional sppiibintt Ly valve angle ee ae WE “JAPAN PATENT No. 7715021-7 GENERAL INFORMATION COUNTER BALANCER Balancer driven gear = Inner face Stank pin “s — ‘\, Balancer drive gear NOTE: Align the three punch marks in line,GENERAL INFORMATION — 1-f OPERATION The mass (or weight) of the counter weight provided 180° on the opposite side of the crank pin is equiva- lent to approximately one half of the inertia force (Fi) that develops in the rising/falling directions of reci- procating engine, However, the counter weight creates a new extra centrifugal foree (Fs ). The inertia force (Fi) and extra centrifugal force (F) combine to become the resultant centrifugal force (E+ ), which occurs at every crank angle. In order to cancel the resultant centrifugal force (F2), the centrif the counter balancer is heeded. The foregoing explains ho gal force (Fa) of é@ inertia and centrifugal forces are reduced by the counter balancer. Crank angle Fy =Inertia force F5=Extta fugal fo fesuliant centrifugal haroe Ont fupal force on counter balancer Fa=Fa Fo-F,=01-9 GENERAL INFORMATION AUTOMATIC CAM CHAIN TENSIONER HOW THE CHAIN TENSIONER OPERATES The spring attached to the cylinder shaft serves to revolve the cylinder, The threaded part of the inside of the cylinder is in contact with threaded part of the tensioner rod. Since the rod guide prevents the tensioner rod from revalving, as the cylinder turns, the tensioner rod is pushed out, The tensioner rod can be retracted by the following procedure: Remove the cap and turn the slotted end of the cylinder shaft with a screw driver in the clockwise direction. Rod quide Guide locating pin Case Thrust washer ‘ \, Tensioner rod \, Spacer Cylinder , O-ring | SpringSPECIAL MATERIALS The materials listed below are needed for maintenance work on the GN250 and should be kept on hand for ready Use. These items supplement such standard materials as cleaning fluids, lubricants, emery cloth and the like. How to use them and where to use them are described in the text of this manual. r Material SUZUKI SUPER GREASE “A” gan00-25010 SUZUKI SILICONE GREASE 88000-25100 , S ca er SUZUKI MOLY PASTE 89000-25140 SUZUKI BOND No, 1215 se000-31110 THREAD LOCK SUPER ™ 3036" ‘89000-32030 Part ® Oil seals ® Cylinder head ec @ Mi ® Wheel bearing ring stem m bearing ® Dust cover Piston pin stem Carr Rocker arm shaft journal and ® Front fork damper rod bolt 1 sprocket balts “clutch allen bolt Page B15 3-26 327 #30 3-30 Page1-1] GENERAL INFORMA) Material Part ® Front fork damper rod bolts THREAD LOCK CEMENT 99000-32040 ® Countershaft bearing retainer screws ® Gearshift cam guide and pawl screws ® Engine oil pump mounting screws ® Pick up coil THREAD LOCK “1342” 99000-32050 ® Mayneto rotor nut THREAD LOCK SUPER "1305" 99000-32100 ® Starter clutch allen bolt THREAD LOCK SUPER eqqgae S48 3-53 3-54 5-2 i i in Part Page 99000-32120GENERAL INFORMATION I-12 PRECAUTIONS AND GENERAL INSTRUCTIONS Observe the following items without fail when disassembling and reassembling motorcycles, ® Be sure to replace packings, gaskets, circlips, O-rings and cotter pins with new ones- CAUTION: Never reuse a circlip after a circlip has been removed from a shaft, it should be discarded and anew circlip must be installed. When installing a new circlip, care must be taken not to expand the end gap larger than required to | slip the circlip over the shaft. After installing a circlip, always insure that it is completely seated in its groove and securely fitted. ® Tighten bolts and nuts from the ones of larger diameter to thase of smaller diameter, and from inside to outside diagonally, with specified tightening torque, ® Use special tools where specified. ® Uce specified genuine parts and recammended oils, ® When more than 2 persons perform work in cooperation, pay attention to the safety of each other, ® Alter the reassembly, check parts for tightening condition and operation. . Treat gasoline, which is extremely flammable and highly explosive, with greatest care. Never use gaso- line 45 leaning solvent. Warming, caution and note are included in this manual occasionally, deseribing the following contents, WARNING ...,....... Personal safety of the rider is involved. and disregard of the information could result in injury. CAUTION .......... For the protection of the motoreycle, the instruction or rule must be strictly adhered to, NOTE.............. Advice calculated to facilitate the repair of the motorcycle is given under this heading. USE OF GENUINE SUZUKI PARTS To réplace any part of the machine, use a genuine SUZUKI replacament part. Imitation parts or farts supplied from any other source than SUZUKI, if used to replace SUZUKI parts, can reduce the machine's performance and, even worse, could fnduce costly mechanical troubles.1-13 GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY M Overall length... Overall width Overall height Wheelbase .. . Ground clearance . 0.0.4.0 2005 6 eb as eee Seat height Dry mass ... ASS ENGINE Type Number of cylinders Stroke Piston displacement ...24.0-.0. +e ere rete seers Compression ratio (SANDURETONS arse gees esters spe eramy re ec ee Pui GIGANBE s. 5 ees taht yee Starter system LUbrication SySt@M «6.0605 ccc eee eet ee TRANSMISSION Clutch Transmission ......-+5 Gearshift pattern ..... Primary reduction Fira PeGUCtiON ira. sc¢k seeeh ike eb harsekaee hwtrleR qe Meer Paties WE OWe. «ache Geveis sepectceai ss atetenk aeoriae pat STEM esac chee eh tpnancteeh cece eerie te as 3rd 4th TCM a asa ere Drive: CHAN: pena ee ace nee 2035 mm 835 mm 1 120mm 1 350 mm 160 mm 740 mm 129 kg Four-stroke, air-cooled, QHC 72.0 mm 61.2 mm . 249 cm* 08.957 _MIKUNI BS34S5, single . Polyurethane foam element , Electric . Wet sump Wet multi-plate type . fspeed constant mesh .. down, 4-up . 3.238 (68/21) 2,733 (41/15) 2.636 (29/11) 1,687 (27/16) ++ 1,263 (24/19) .. 1,000 (20/20) ,- 0.818 (18/22) . DAIBO D.1.D. 520UB or TAKASAGO RE5S205U . 100 linksELECTRICAL Ignition type Ignition timing .. RRND pik we tae BBWEEV ey cdc otsce ‘ BUERM RTD Oe cee 5. Headlight .... | UML PEIIA RS ec Pr rer se. reser c de ey attest Turn signal light , Turd signal indicator light Neutral indicator light | Spsedometer light MMOIGITIETEVALCUN Days aor eitte coals. eee fapares asa castle Gd ah High beam indicator jight ..... PemIMOROITVIGHY 4 shots oat a teas ae CHASSIS Front suspension Rear suspension SHEEFING ANGIE sae ss PRM Pe og sins cig cece est itesllher gaat ied asa GENERAL INFO ION 1-14 . Transistorized 10° B.T.D.C, below 1 700 r/min and 35° B.T.D.C. above 3 000 r/min .NGK D8EA or NIPPON DENSO Mae Bil 2 ann weeps . For £-01, 24 NGK BRSES-L or NIPPON DENSO X24ESR-U ssetiy yee FOr the others 12V 43.2 kC (12 Ah)/10 HR ». 165A .12V 45/45W oo... ....... ET, 02, 06, 24 2 46/40OW ee eee, HDG V2V BOVSBW) cis vere ERB .12V 3.4W .12V 8/23W ee eS GAT oo re EOS 22,26 12V 23W cree ee pg Or E01,06,24, 26: TEV 2 TW tia sede ed eee «FOr the others 12V 34w -12V3 .12V 2.4w oS Ws cies aa, easy phe 12V 2.4W u SV is rnin rege sedges .. Except E-28 For E-01, 06, 24 LAV AW ee cana en FOr therothers . Telescopic, coil spring, oil dampened . Swinging arm, oll dampened, spring S-way adjustable ». 40° .. b9*45¢ - 105 mm SPMRITER OAT GME ee Nee as Geeang fel ay ceo x cms person de Front brake ....-. Rearbrake .. Front tire size PE a Fl 5 ae ed oe CAPACITIES Fuel tank including reserve RMN Westie alsa an aw BTOHPMOIR-ON cacy hea eevee SPURRED et iat) a Seda aes Wee hea 8 . Internal expanding 24m . For E-28 Dise brake ..... . For the others . Internal expanding 4.60816 4PR).. 0080.4 3.00 S18 4PR For the orhers 120/90 16635... . . For E22 -10:31L - 2.04 eerie L- . 216ml * The specifications subject to change without notice.ld GENERAL INFORMATION TSCC (TWIN SWIRL COMBUSTION CHAMBER) GN250 models use SUZUKI 's Unique TSCC engine design, which is internationally acclaimed for its dura- bility and performance. TSCC describes the heart of the engine, the Twin Swirl Combustion Chamber, What the TSCC angine series does better than conventional 4-strake engines, either 2-valye or 4-yalve, is im prove on the two major factors which affect engine performance, charge burning efficiency and intake charging efficiency. First, rge burning efficiency. The TSCC* system consists of a subtle, yet unique shape casted into the ach of the two intake valves is set into adjoining semi-hemispherical depressions in the head. During the intake stroke these depressions channel the incoming head. fuel/air mixture to form two separate high-speed swirls, During the compression stroke the squish areas machined in the front and the rear of the cylinder head's combustion chamber accelerate the speed of the swirls. Thus, when the spark plug ignites the mixture, the flame spreads rapidly and completes the combustion more quickly. To further aid burning efficiency, the spark plug is centrally located, the ideal location. This results in the shortest possible path for the flame to travel. “JAPAM PATENT No. 771502PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES SC CONTENTS PERIODIC MAINTENCE SCHEDULE :-cc0seerreeerttretrreeernerennie | MAINTENANCE PROCEDURES -------+--++++--s--0rrrreecrer nett 22 | BATTERY 11tctsrtctesceeeceeeesce rete neeete ree see eran eeseasscuucuanensanses 2-2 CYLINDER HEAD NUTS, EXHAUST PIPE BOLTS | AND NUT otccccvcccce reeset rete ce eeeerne en eeeeneeeectssestaeeaneaaeaeectees 2-3 AIP CLEANER oss0s0s-sseeceseeseeseteesensenerseneeneernesestsseenscnes 2a | VALVE GLEARIANCE -1---eeceescecrsreneescrees ee esernn ene raecnn tae asnes 2-5 SPARK PLUG coc crsvrsecsecenecc ete tt ernie es resaeeseaseaena ere neenennsa ts 2-6 FUEL, LINE stessssecseensnerscerscsssenseensesenszenrneeteesanensepersegtes 2-6 FUEL STRAINER: +:-0-:-00e0c cere cerns renter ren ese a nena en rene staat 2-6 ENGINE OL -cs1-cecrececseeee ees ceeceetee eee ene seca es ctenseneeneanennen ins 2-7 ENGINE OIL FILTER 0c00ce-cssscsecetccece errr rerenaeetennnnneaeenns 2-7 ENGINE IDLE SPEED «:-+--++-+-2:-0s0esesset renee sas tennenaenncceecnes 2-8 LUT GH esseeveccessceeseeetecntcensenauannenesstteesasenteetenennensesenes 2-9 DRIVE GHAIN --0:c2cccecrecrecerer ere neree tere cere cta tenn eeeeeanenannenges 2-9 BRAKES iccessccseeeeeeesteneeensabecnanteenarnseraetarneatesenessneanes ees 2-11 | TIRES AND SPOKES +-::--:e-sscecceres erst etamer rece ere nese ennnenen ts B15 | STEERING 0:scccceesceceececcnseenseceeeetneeneesceseseeeececcntenrnnaney 2-16 | FRONT FORK-+-..0-sssr rte centraa valpeedddfaiaatei ate 2-16 | CHASSIS AND ENGINE BOLTS AND NUTS: 7-0-7 2-17 |2-] PERIODIC MAINTENANCE AND TUNE-LIP PR JRES PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Traveled distance is expressed in terms of hours, NOTE: More frequent servicing may be performed on motorcycles that are used under severe conditions, PERIODIC MAINTENANCE CHART ENGINE AND CHASSIS INTERVAL: This interval should — km | 4,000 5,000 | 10,000 15,000 be judged by odometer reading or + } { 1 | Page month, which cones first month 3 15 | 30 45 Battery | l | | 2-2 | | | Cylinder head nuts, exhaust pipe bolts and nuts T T ap | iF 2-3 Air cleaner C | Cc | Cc 2-4 } } } l Valve clearance | \ ! | ! | 2.6 a Spark plug c R c | 26 | | | | | | Fuel line | 26 | Replace avery four years Fuel strainer i | ; | S.° ~ 26 “Engine ail and oil filter R R A | RA 27 rpm \ | I | \ 2-8 | | | : Clutch | | | | | 2.9 \ \ | I | I Drive chain M 1 29 Clean and lubricate every 1,000 km Brakes | | | | | 2-11 5 change fluid every 2 years | | | | 2-15 I | 216 Front fork — I ! I 2-16 Chassis bolts and nuts T T T T 947 Note: T = Tighten, | = Inspect, R = Replace, C = Clean The specific valve clearance, engine oi! and idle rpm appears on the vehicle emission control information label.PERIDDIC MAINTENANCE AND TUNE-UP PROCEDURES 2-2 MAINTENANCE PROCEDURES This section describes the service procedures for each section of Periodic Maintenance. BATTERY 5000, 10000, 15 000 km The battery must be removed to check the électrolyte level and specific gravity. Remove the frame cover. Remove battery — lead at the battery terminal, Remove battery > lead. Remove battery fram the frame. Check electrolyte for level and specific gravity, Add distilled water, as necessary, to keap the surface of the electrolyte above the LOWER S) level line 1) but not above the UPPER level line : 5 Ieper For checking specific gravity, use a hydrometer to determine the charged condition, 09900-28403 Hydrometer Standard specific _ 1.28 at 20°C (68"F) gravity An S.G, reading of 1.22 (at 20°C) or under means that the battery needs recharging off the machine: take it off and charge it from a recharger. Charg- ing the battery in place can lead to failure of the fequiator/rectifier, ® Jo install the battery, reverse the procedure described above. - WARNING: When installing the battery lead wires, fix the + lead first and — lead last, * Make sure that the breather pipe is tightly secured and undamaged, and is routed as shown in the figure, breather pipe2.3 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES CYLINDER HEAD NUTS, CYLINDER NUTS, EXHAUST PIPE BOLTS 1000, 5 000, 10 000, 15 000 km ee ———— ee | Cylinder head nuts a Remove the seat and fuel tank. (Reter to page 3-2) @ Remove the cylinder head cover. (Refer to page 3-8) ® Tighten the four 10-mm nuts and two 6-mm nuts to the specified torque with a torque wrench, when engine is cold. Tightening torque 35 — 40 Nem F (3.5 — 4.0 kam) Tightening torque 819 Nm (0.8 — 1.2 ka-m) e When installing cylinder head cover, apply Suzuki Bond No. 1215 to the mating surface. (Refer to page 3-31), 99000-31110 Suzuki Bond No. 1215 Cylinder nuts ® Tighten the two 6 mm nuts to the specified torque. 7-11 N-m Tightening torque (0.7=1,1 kg-m) Exhaust pipe bolts and muffler clamp bolt Tighten the exhaust pipe bolts and muffler clamp bolt to the specified torque. Tightening torque Exhaust pipe | 9—12N-m bolts (0.9 — 1,2 kg-m)PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 24 AIR CLEANER ELEMENT 6000, 10 000, 15 000 km ff the air cleaner is clogged with dust, intake re- sistance Will be increased with a resultant de- crease in power output and an increase in fuel consumption, Check and clean the element in the following manner. ® Remove the left frame cover ® Remove the screw and take out the air cleaner element assembly. e Separate the polyurethane foam element from the element frame. | NOTE: When install the air cleaner case cover, place the “UP mark upward. « Fill a washing pan of a proper size with non- flammable cleaning solvent. Immerse the ele ment in the cleaning solvent and wash it clean, « Squeeze the cleaning solvent out of the washed element by pressing it between the palms of both hands. e immerse the element in motor oil, and squeeze the oil out of the element leaving it slightly wet with ail. NOTE: Do not twist or wring the element because it will tear or the individual cells of the element will be damaged. CAUTION: Inspect the element carefully for rips, torn seams, etc. If any damage is noted, replace the element. Element Non flammable Cleaning | Solvent > Se Motor oil =e)PERIDDIC MAINTENANCE AND TUNE-UP PROC VALVE CLEARANCE 1000, 5 000, 10 000, 15 000 km Excessive Valve clearance results in Valve noise and insufficient valve clearance results in valve damage and reduced power. At the distances indicated above, check and adjust the clearance to the following specification. The procedure for adjusting the valve clearance is as follows: ® Remove the seat and fuel tank. e Remove spark plug, valve inspection caps, and valve timing Inspection plug, =» Remove the magneto cover cap and rotate the magneto rotar with the 22-mm box wrench to set the piston at (TDC) of the compression stroke. (Rotate the rotor until the rotor is aligned with the center of hale on the eT line Oh) on the 2.) @ thickness gauge to the valve stem end justing screw on the rocker arm. crank ian and t Thickness gauge 09900 — 20803 Valve clearance specifications IN. | 0,03 — 0,08 mm 7 at tae 0.13 mm } EX. \ , 0,08 | 4 Til — © li clearance is off the specification, bring it into the specified range by using the special tool. 09917 — 14910 Tappet adjust driver CAUTION. | Both of the valve clearances, right and left, should be as closely set as possible. Reinstall spark plug, valve inspection caps, valve timing inspection plug and magneto cover cap, NOTE: Valve clearance is to be checked when the | engine is cold. Both the intake and exhaust valves must | be checked and adjusted when the piston is at Top—Dead—Center (TDC) of the compres- sion stroke.1 PROCEDURES PERIODIC MAINTE SPARK PLUG § 000, 10 000, 15 000 km Remove the carbon deposits with a wire or pin and adjust the spark plug gap to 0.6 — 0.7 mm, measuring with a thickness gaque. When removing carbon deposits, be sure to observe the appearance of the plug, noting the color of the carbon deposits, The color observed indicates whether the standard plug is suitable or not. If EE =I the standard plug is apt To get wet, a hotter plug should be used. If the standard plug is apt ta = ; £01.24 Jen? 06 22,26 29 9 eat {porcelain is whitish in appearance), re ; NGK DEA ot NGK DRIVES or lace with a colder one. Houe NIPPON DENSO | NIPPON DENSO spark RIVE | czas) “22ESR-U NGK D8EA or | NGK BRBES-L or ate jug | NIPPON DENSO | NIPPON DENSO +R Rate | Xa ES XP4ESR-U Pane NGK D9EAor | NGK DRBES or oS RERE: NIPPON DENSO | NIPPON DENSO spark plug PS | xa7es.u XO7ESR-U Standard FUEL LINE 7000,5 000, 10000, 15000 km | Replace every four years. FUEL STRAINER 7000, 10 000 km | [f the fuel strainer is dirty with sediment, fuel will not flow smoothly and loss in engine power may result. Clean the strainer cup with non-flammable clea- ning solvent,#7 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES a ENGINE OIL 1000, 5 000, 10 000, 15 000 km The oil should be changed with the engine hot. The procedure is as follows: Support the motorcycle by center stand. Drain the oi) by removing the drain plug (1) and filler cap @. Fit drain plug () securely and add fresh oil through the filler, The engine will hold about 1.3 L of oil. Use 10W/40 viscosity of oil under API classifica tion of SE or SF. Start up the engine and allow it to run for several seconds at idling speed. Shut down the engine and wait about one minute, Then check the oil level in the oil level window @). The motorcycle must be in a level, upright position for accurate measurement, lf the level is below the “F" mark, add oil until the level reaches the “’F" mark. ENGINE OIL FILTER 1.000, 5 000, 10 000, 15 000 km Replace the oil filter in the following manner: e Drain engine oil by removing the drain plug. e Remove the three bolts securing the filter cap. © Take off the cap, and pull out the filter.PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 28 # Replace the filter with @ new one. ® Before putting on the filter cap, check to be sure that the filter spring and the O-ring are installed correctly, ® Replace the filter cap and tighten the bolts se- ourely. ® Pour in engine oil and check the level. | NOTE: Pour about 1,3 L of engine oil into the engine | only when changing oil and replacing oil filter at the same time. When performing engine overhaul, the amount of oil to be replenished is 1.7 L. CAUTION: When reassembling the oil filter, make sure to | check the oil filter installed as shown in illust- ration. If the filter is installed improperly, the serious engine damage may result. | ENGINE IDLE SPEED 1000, 5 000, 10 000, 15 000 km | dling adjustment —_ NOTE: i Make this adjustment when the engine is hot. @ Start up the engine and set its speed at anywhere between 1200 and 1300 r/min by turning throttle stop screw (1). | Engine idle speed 1250+ 50 r/min | Throttle cable play There should be 0.5 — 1.0 mm play ) on the throttle cable. To adjust the throttle cable play: ® Jug on the throttle cable to check the amount of play. « Loosen the two lock nuts @) and turn the adjuster @) in or out until the specified play is obtained. 6 Secure the lock nuts while holding the adjuster in place, | Throttle cable play | 05 —1.0 mm e a _CLUTCH 7 000, 5 000, 10 000, 15 000 km | Clutch play should be 4 mm as measured at the clutch lever holder before the clutch begins to disengage. If the play in the clutch is incorrect, adjust it in the follawing way: ® Loosen the lock nut on the lever adjuster screw, e Screw the adjuster on the clutch lever holder all the way in. ® Loosen clutch cable adjuster lock nuts (1), © Turn the clutch cable adjuster @) in or out to acquire the specified play, e Tighten lock nut while holding the adjuster in position. The clutch cable should be lubricated with a light weight oil whenever it is adjusted. DRIVE CHAIN 1 000, 5 000, 10 000, 15 000 km Clean and lubricate every 1000 km Drive chain Visually inspect the drive chain for the below. listed possible malconditions. (Lift the rear wheel by placing the center stand, and turn the rear wheel slowly by hand, with the transmission in NEUTRAL.) Inspect for: |. Loose pins 2, Damaged rollers 3. Rusted links 4, Twisted or seized links 5, Excessive wear lf any defects are found, the drive chain must be replaced. e Wash the chain with kerosene. If the chain tends to rust faster, the interval must be shortened. e After washing and drying the chain, lubricate it with chain lube or gear oi! SAEF9O., 79 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 4mmPERIODIC MAINTENANCE AND TUNEUP PROCEDURES 2-10 "heck the drive chain for wear and adjust the thain tension as follows: s Loosen axle nut () after pulling out cotter pin @ and loosen the lock nut (2) . e Adjust the drive chain carefully by tightening the adjusters (4), Chain wear —_ ® Count out 27 pins on the chain and measure the distance between Ist and 21st. If the ) ; : 19202 distance exceeds 324.2 mm, the chain must be 123 ee 20 21 replaced. Chain Sag @ Loosen the adjuster (4) until the chain has 25 = ———— — 85 mm of sag at the middle between engine | and rear sprockets. The mark ‘5 on both chain adjusters must be at aesee sere Ry, | the same position on the scale to ensure that the front and rear wheels are correctly aligned. e After adjusting the drive chain, tighten the axle nut G1) securely and lock with cotter pin a (@). Always use a new cotter pin. a 25 = 35 mm 2| »211 PERI BRAKES 1000, 5000, 10 000, 15 000 km Replace hoses every 4 years | Change fluid every 2 years. FRONT BRAKE SHOE TYPE Squeeze the front brake lever firmly and measure the distance between the lever and the throttle grip. The distance (1) should be 20 — 30 mm, lf adjustment is necessary, slacken the cable by loosening the lock nut and screwing the adjuster on the front brake lever holder all the way in. Turning the adjuster (2 distance. to obtain the specified Brake lining wear limit This motorcycle is equipped with brake lining wear limit indicators on front brake. As shown in the illustration at right, at the condition of normal lining wear, an extended Jine fram the index mark on the brake camshaft should be within the range embossed an the brake panel with the brake on. To check wear of the brake lining, follaw the steps below. @ First check if the brake system is properly adjusted, ® While operating the brake, check to see that the extension line from the index mark is within the range on the brake panel. ® |f the Index mark is outside the range as shown in the illustration at right, the brake shoe assem- bly should be replaced to ensure safe operation. 7 MAINTENANCE AND TUNE-UP PROCED JAES The extension line of the index mark is within the range. The extension line of the index mark is outside of the range.PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-12 5 TYPE FLUID LEVEL jort the motorcycle body on the center and place the handlebars straight, | the brake fluid level by observing the lower limit line on the brake fluid reservoir. Se When the level is below the lower limit line, ~ replenish with brake fluid that meets the follaw- ‘ing specification. ‘Shecification DOT3, DOT4 and Classification | or SAE J1703 = ee 2202 | | SUZUKI Brake fluid WARNING: The brake system of this motorcycle is filled with a glycol-based brake fluid. Do not use or mix different types of fluid such as silicone- based and petroleum-based fluid for refilling the system, otherwise serious damage will ba caused. Do not use any brake fluid taken from old or used or unsealed containers. Never re-use the brake fluid left over from the last servicing and stored for long periods, | ) WARNING: | Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted | surfaces. | Check the brake hoses for cracks and hose | joint for leakage before riding. BRAKE PADS Wearing condition of brake pads can be checked by observing the red limit line (1) marked on the pad, When the wear exceeds the limit line, replace the pads with new ones. (see page 6-11) BRAKE LIGHT SWITCHES Adjust brake light switch so that brake light will come on just before a pressure is felt when the brake lever is squeezed,AIR BLEEDING THE BRAKE FLUID CIRCUIT Air trapped in the fluid circuit acts like a cushion to absorb a large proportion of the pressure devel- oped by the master cylinder and thus interferes with the full braking performance of the caliper brake. The presénce of air is indicated by “spangi- ness” of the brake lever and also by lack of braking force. Considering the danger to which such trap- ped air exposes the machine and rider, it is essen- tial that, after remounting the brake and restoring the brake system to the normal condition, the brake fluid circuit be purged of air in the following manner: e Fill up the master cylinder reservoir to the "HIGH" level line. Replace the reservoir cap to prevent entry of dirt ® Attach a pipe to the caliper bleeder valve, and insert the free end of the pipe into a receptacle. Bleeder valve 7— Nem tightening torque (0.7 — 0.9 kg-m) @ Squeeze and release the brake lever several times in rapid suec ession, and squeeze the lever fully without releasing it, Loosen the bleeder valve by turning it @ quarter of a turn so that the brake fluid runs into the receptacle; this will remove the tension of the brake lever causing it to touch the handlebar grip. Then, close the valve, pump and sue the lever, and open the valve. Re- peat this process until the fluid flowing into the receptacle no longer contains air bubbles. NOTE: Replenish the brake fluid reservoir as neces- sary while bleeding the brake system. Make sure that there is always some fluid | visible in the reservoir. L =| ® Close the bleeder valve, and disconnect the pipe, Fill the reservoir to the “HIGH” level line. CAUTION: Handle the brake fluid with care: the fluid raacts chemically with paint, plastics, rubber materials, etc,PERIOD MAINTE ‘REAR BRAKE Bang the brake pedal to a position about 10 mm. This is effected by turning the brake pedal stopper 1 (behind the frame). Be sure to tighten the lock nuti@securely after setting the bolt, ee brake height Hi 10 mm | After adjusting the rear brake height, adjust the brake padal travel. First set the pedal at a pasition for comfortable riding by wening the brake pedal stopper 1), and then adjust the free travel (3) to 20-30 mm. [fF adjustment is necessary,turn the rear brake adjuster 4) to obtain the specific play. ae Brake pedal travel | 20 —30mm Brake lining wear limit This motorcycle is equipped with brake lining wear limit indicators on rear brake, As shown in the illustration at right, at the condition of normal lining wear, an extended line from the index marl on the brake camshaft should be within the range embossed on the brake panel with the brake on. To check wear of the brake lining, follow the steps helow, i hej ste ic AA We = Bes ot * aye isthe) brabess Vina isGi op ete ad The extension line of the index mark is within eo the range. | & While operating the brake, check to see that the extension Jine from the inde» mark is within the range on the brake panel. « |f the index mark is outside the range as shown in the illustration at right, the brake shoe assem- bly should be replaced to ensure safe operation, The extension line of the index mark is outside of the range.TIRES AND SPOKES 7 000,5 000, 10 000, 15 000 km { wd Tire Inspect the tires for wear and damage; and check the tire tread depth as shown, Replace a badly worn or damaged tire. A tire with its tread worn down to the limit (in terms of tread depth) must be replaced. Tread depth service limit Front 1.6mm Rear 20mm Check the tire pressure, and examine the valve for evidence of air leakage. TIRE PRESSURE [ NORMAL RIDING COLD INFLATION | CONTINUOUS HIGH SPEED RIDING § F G BUAL RIDING | RIDING BUAL RIDING TIRE PRESSURE SOLD IBIOINEL - SOLD RID — | kPa kg/cm? kPa kg/em= kPa re] ka/ern? kPa Kg/em? | \ a | eRe ee FRONT | 17815 1.75 17515 1.75: 1.75 200271 2.00 | REAR 20027) 3.00 22531) 225 | 2.25 25036 | 950 Spoke Check to be sure that all nipples are tight, and retighten therm as necessary using special tool, Spoke nipple wrench 09940-60113 4—5 Nom Tightening torque ; Beer anlteede (0.4 —0.5 kg-m} CAUTION: Over or under-tightaning may cause spoke breakage.20010 MAINTENANCE AND) TUNEUP PROCEDURES STEERING . 7000, 5 000, 10 000, 15 000 km ‘| Steering stem bearings should be adjusted properly for smooth turning of the handlebars and safe run- ning. Steering which is too stiff prevents smooth move- ment of handlebars. Steering which is too loose will cause vibration and damane to the steering bearings. Check to see that there is no play in the front fork attachment. lf the play is found, perform steering bearing ad- justment as described in page 6-34 of this manual. Tightening torque ITEM = | mm ka-m B® | Handlebars clamp bolts | 12-20 | 1.2-20 tes e | Steering stem upper 16-25 15-25 clamp balt Steering stem head bolt 35 — 45. | 3.5 —4.5 Front fork upper cl a eRe on a0) pei kd . | Front fork lower clamp ae: | : bolt | 1s—25 | 15-25 Master cylinder mounting 5-8 05-028 bolt FRONT FORK 5 000, 10 000, 15 000 km | Inspect the front fork for oil leakage, scoring and scratches on the outer surface of the inner tube every 5000 km and replace the defective parts, if necessary.CHASSIS Bolts and Nuts ENGINE Mounting bolts 1000, 5 000, 10.000, 15 000 km The nuts and bolts listed are important parts, and they must be in good condition for safety, They must be retightened, as necessary, to the specified torque with a torque wrench. Tightening torque ITEM Brake cam lever bolts (Front and Rear) (2) Rear torque link nut (3 Swing anm piver out | (4 | Front axle nut (5) | Frant axle clamp nut fe | Rear axle nut 7) | Engine mount bolts 8 Rear shock absorber ~ | fitting nut 9) | caliper mounting bolt ‘oh il | Caliper axle bolt Brake dise bolt AP | Brake hose joint bolt N-m kg-m §-8 | 05-08 | 1.0 = 1.5 10=15 50-80 |50-80] | 96-62 |3e—52 15 — 25 20—30 | 2.0-3.0 25-40 | 25-40 1820 | 716-2.0 15—26 | 15—25 25-35 | 25-35UP PROCEDURES 218 D TUNE ANCE AN VAINTEN a] ao So a= (ARBURETOR ITEM | — T Carburetor type fore size ||, 0. No. {Idle r/min. Fuel level Float haight | Main jet (M. J.) == === (M. A. J.) | Main air jet | Jet needle (J. No) —— Needle jet | Pilot jet (P. J.) By pass (B. P.) | Pilot outlet (P..O.) ivcsJ T (G. 5.) (N. J.) Valve seat | Starter jet | Pilot screw (P.S.) | Pilot air jet (P. A. JL) Throttle cable play SERVICING INFORMATION Unit: SPECIFICATION MIKUN| BS3455 34 38310 1250 +50 r/min. SDF9O-3 Py 242.5 1,0, 0.7, 0.8, 0.8 7 40 2 turn out = 150 7-20) mmSERVICING INFO SUSPENSION | ITEM Front fork stroke b Front fork spring free length Front fark ei] level Rear wheel travel Swing arm pivot shaft runout STANDARD 140 FUEL + OIL Units mm NOTE ITEM SPECIFICATION Fuel type Fuel tank including reserve Engine oil type and grade Engine oil capacity | Front fork oil type Front fork ail capacity (each leq) Gasoline used should be graded 85-95 oc- tane ot higher. An unleaded or low-lead type gasoline is recommended. 16:3. 2.0 L SAE 10W/40 SE or SF Change 1300 ml [Filter 1400 ml change Overhaul 1760 mi Fork oil = 10 216 ml== conreNts—_—_—— COMPRESSION PRESSURE AND OIL PRESSURE: go7 ENGINE REMOVAL AND REMOUNTING::---r-- 77°" 3-2 UPPER END COMPONENTS DISASSEMBLY ~---"" Ba, _ UPPER END COMPONENTS INSPECTION BOMTREELVIGING:-oscnsccccsscceceereemeee ree 313 yppER END COMPONENTS REASSEMBLY 7" 3-25 LOWER END COMPONENTS DISASSEMBLY -----"" 3-33 LOWER END COMPONENTS INSPECTION BASIS EPAVIGING <---sssccecceeress cree cecreeser ener tesee een 3-41 LOWER END COMPONENTS REASSEMBLY «0 3-4641 SERVICING ENGINE COMPRESSION PRESSURE AND OIL PRESSURE COMPRESSION PRESSURE NOTE: * Before testing the engine for compression Pressure, make sure that the cylinder head nuts and bolts are tightened to specified torque values and valves are properly ad- | justecl, | Have the engine warmed up by idling before testing it. 09915-64510 09915-63710 i B [c OMpression gauge ® Remove spark plug, e Fit the compression gauge taking care to make the connection absolutely tight. to the plug hole, Twist the throttle grip into wide-open position. ® Crank the engine Several times with the starter motor, and read the highest gauge indication as the compression of the cylinder, Compression pressure Standard | Limit 10—14ko/cm* | 8 kg/em* A low compression pressure may indicate any of the following malfunctions: * Excessively worn cylinder wall * Worn piston or piston rings. © Piston rings stuck in the grooves * Poor seating contact of valves * Detective cylinder head gasket. When the compression pressure noted is down to or below the limit indicated above, the engine must be disassembled, inspected and repaired as required to overhaul the engine, with these five malcon- ditions in mind. OIL PRESSURE ® Instal| the oil pressure gauge (g) in the pasition shown in the illustration, ® Warm up the engine as follows. Summer approx. 10 min, at 2.000 r/min. Winter approx. 20 min. at 2 000 r/min, ® After the warming up operation, increase the engine speed to 3 000 r/min, and read the oil pressure gauge Oil pressure Above 0,30 kg/om?, Below 0.70 kg/em? at 3 000 ¢/min, Oil pressure gauge | 09915-74510 lf the pressure is too low, it means that the oil pump is internally worn or otherwise defective and the complete oi] pump unit needs to be replaced,SEAVICING ENGINE ENGINE REMOVAL AND REMOUNTING ENGINE REMOVAL Before taking the engine out of the frame, thorough- ly clean the engine with a suitable cleaner. The procedure of engine removal is sequentially explained in the following steps. « Take off the right and left frame covers. @ Disconnect the and © lead wires of battery. First, disconnect the = lead wire, s Al CAUTION: ® Turn the fuel cock lever “OFF” position, ® Jake off the fuel hose, @ Loosen and remove the seat mounting bolts and rear shock absorber nut, # Take off the fuel tank by removing the mounting bolts. $234 SERVICING ENGINE ® Remove the tachometer cable, ® Take off the clutch lever by removing the clutch lever bolt and adjuster lock nuts, A | * Disconnect the generator lead, signal generator | lead and gear position lead. | \| « Take off the plug cap. ® Take off the engine sprocket cover.SERVICING ENGINE 34 « After flattenning the lock washer, remove the nut by applying the rear brake. # Push forward the rear wheel after loosening the rear axle nut, chain adjusters and adjuster lock nuts, ® Take off the engine sprocket. # Take off the breather pipe. ® Disconnect the lead wire of starter motor, ® Remove the exhaust pipe bolts and muffler clamp balt.46 SERVICING ENGINE ® Loosen the throttle cable adjuster lock nuts. ® Take off the throttle cable. ® Remove the carburetor by unscrewing the re- tainer screws, s Remove engine mounting bolts and brackets, @ Use both hands, and lift the engine from the frame. NOTE: The engine must be taken out from the right side. CAUTION: Be careful not to draw out the swing arm pivot shaft completely from the left side swing arm pivoting hole. Insert the shaft or rod into the right side pivoting hole from the right side of the frame to keep the alignment of the frame holes and swing arm pivoting holes. ENGINE REMOUNTING The engine can be mounted in the reverse order of removal. ® Temporarily fasten the engine mounting bracket before inserting the engine mounting bolts. NOTE: The engine mounting nuts are self-lock nuts. Once the nut has bean removed, it is no longer of any use, Be sure to use new nuts and tighten them to the specified torque. ® After remounting the engine, following adjust: Mens are necessary. Throttle cable Clutch cable Drive chain Rear brake pedal Idling speed (Page: 4-— 9) (Page: 2— 9) (Page: 2— 9) (Page: 2— 11} (Page: 2— 8) | ) |SEAVICING ENGINE 36 : ‘ ; : Ma Tightening torque for engine mounting bolts 3.7-4.5 kg-m Tightening 37 —45 Nom torque (3.7 — 4.5 kg-m) MB 3.7-4.5 kam A ® Tightening the exhaust pipe bolts and muffler 7 B// clamp to specified torque, } | Tightening 9-12 Nem Torque (0.9 = 1.2 kg-m) ~~ @— ma 3,7-4,5 kgm Tighten the engine sprocket nut. | Tightening 80 — 100 Nem (8.0 — 10.0 kg-m) torque Pour 1.7 L of engine oil SAE 10W/40 graded SE or SF inta the engine after overhauling engine. © Start up the engine and allow it run for several seconds at idle speed. About one minute after stopping engine, check oil level, lf the level is below the “F’ mark, add oil until the level reaches the “F" mark, Installing position for clutch release arm * Align the release arm slit surface with the notch mark on the release cam shaft. Slit Notch Mark3-7__ SERVICING ENGINE 7 UPPER END COMPONENTS DISASSEMBLY CYLINDER HEAD COVER rn AND CYLINDER HEAD NOTE: * If top end repair only is being performed, it is not necessary to remove the engine from the frame, * As already noted, seat, fuel tank, side covers etc, must be removed. ® Drain engine oil. ® Remove gear shift lever. : ® Remove magneto cover cap and inspection plug. = "T" type hexagon wrench (5 mm} 09911-73730 ut i) ® Remove chain tensioner,§ Remove valve inspection caps and spark plug. * Bring the piston to top dead center. NOTE: When removing cylinder head cover, piston must be at top dead center on compression | stroke, @ First, remove the tachometer gear. ® Next, loosen the cylinder head cover bolts in the order inclicated in the illustration and detach the cylinder head cover. | NOTE: When removing cylinder head cover, do not remove conically recessed top bolts. ® Detach the camshaft end cap. ® Flatten camshaft sprocket lock washer, ® Remove camshaft sprocket bolts and detach the camshaft, NOTE: The cam chain tensioner bolt (1) is to be removed only when disassembling the engine. 3} CAUTION: Do not drop camshaft drive chain, pin and sprocket into the crankcase. SERVICING ENGINE 3839 SERVICING ENGINE e Loosen the six cylinder head nuts diagonally, than detach the cylinder head. NOTE: If it is difficult to remove the cylinder head, gantly pry it off while tapping the finless por- tion of the cylinder head with a plastic hammer, Be careful mot to break the fins. e Remove rocker arm shaft set bolts. ® Pull out the rocker arm shafts with pliers.SERVICING ENGINE 210 # Compress the valve spring by using the special tool, | Valve lifter 09916-14510 | @ Take off the valve cotters from valve stem, Tweezers 09916-64510 e Take out the valve spring retainer and spring. © Pull out the valve from the other side.311 SERVICING ENGINE ® Remove oil seal, using long-nose pliers. ® Take out the spring seat. e Remove valve guide. ide Install- Valve guide insta 09916-44910 er and remover ® Remove cylinder nuts. Remove the cylinder by using the special tool. Cylinder disassembling 09912-34510 tool CAUTION: | lf tapping with plastic hammer is necessary, do not break the fins.SERVICING ENGINE 3-12 Clean rag over the cylinder base to fit piston pin circlip from dropping into fase and then, remove the piston pin with long-nose pliers. © Remove piston pin. [Piston pin putter 09910-34510$id SEAVICING ENGINE UPPER END COMPONENTS INSPECTION AND SERVICING CYLINDER HEAD COVER DISTORTION After removing sealant (SUZUKI BOND No, 1215) from the fitting surface of the cylinder head cover, place the cylinder head cover on a surface plate and check for distortion with a thickness gauge, Check points are shown in illustration. | Service limit | 0.05 mm | If the distortion exceeds the limit, replace the cy- linder head cover, ROCKER ARM SHAFT O.D. Measure diameter of rocker arm shaft. Standard | 11.966 — 11.984 mm ROCKER ARM I.D. When checking the valve rocker arm, the inside diameter of the valve rocker arm and wear of the camshaft contacting surface should be checked. Standard 12.000 — 12,018 mm CAMSHAFT The camshaft should be checked for runout and also for wear of cams and journals fi the engine has been noted to give abnormal noise or vibration or to lack output power, Any of these maleonditions could be caused by camshaft worn down of distorted to the service limit. Exhaust close f (A.T.D.C.) Inlet open (B.T.DC.) 4. Exhaust open | "+ (B.B.0,C.} B.D.c. Valve timing diagram Intet clase (4.B.0.C.)a4 SERVICING ENGINE CAMSHAFT CAM WEAR Wom-down cams are often the cause of mistimed | | valve operation resulting in reduced output power. —_ | rank 5 oe 2 7 The limit of cam wear is specified for both intake | ‘ | and exhaust cams in terms of cam height Hi, | f | which is to be measured with a micrometer. Re- : : (H) place camshafts if found it worn dawn to the limit. a [; Micrometer | | ss | : I | (25 — 50 mm) 09900 — 20202 | Cam height Service limit Height ‘H Intake cam | 34.690 mm Exhaust cam 34,730 mm CAMSHAFT JOURNAL WEAR Determine whether each journal is worn down to the limit or not by measuring camshalt journal oil clearance with the camshaft installed. Use plasti- gauge to read the clearance, which is specified as ollows: Plastigauge 09900-22301 | Camshaft journal oil clearance Service limit 0.15 mm Cylinder head cover tightening torque Tightening 9—10N-m | Torque (0.9 — 1.0 kg-m) NOTE: At the stage when gasket material has been removed from fitting surfaces of cylinder head and cover, and before SUZUKI BOND No. 1215 has been applied, fit the cylinder head cover and tighten to the torque specified, J