SUZUKI SA el SOAFOREWORD This manual contains an introductory descrif tion on the SUZUKI FX150 and procedures for its inspection/service and overhaul of its main com- ponents. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections as a guide for proper inspection and service. This manual will help you know the motorcycle better so that you can assure your customers of fast and reliable service. * This manual has been prepared on the basis of the latest specifications at the time of publication. If modifications have been made since then, differences may exist between the content of this manual and the actual motorcycle. + Mlustrations in this manual are used to show the basic principles of operation and work procedures. They may not rep- resent the actual motorcycle exactly in detail + This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you. Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the | services described in this manual. Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider and passenger. LION SUZUKI MARKETING SDN BHD (199008-4) Service Department ©COPYRIGHT LION SUZUKI MARKETING SDN BHD 1997 GROUP INDEX GENERAL INFORMATION | PERIODIC MAINTENANCE ENGINE FUEL AND LUBRICATION SYSTEM CHASSIS ELECTRICAL SYSTEM SERVICING INFORMATIONeee” HOW TO USE THIS MANUAL | oer WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section eas- ily. | 4. The contents are listed on the first page of each | section to help you find the item and page you need. i COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit, is its exploded view Work instructions and other service information such as the tightening torque, lubricating points and locking agent points, are provided. ' 5 4 Example: Front whee! | Nem | kgm Eg 53 23 23 © Front axle @ Front axle nut @ Brake disc boltSYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table. SYMBOL DEFINITION ‘SYMBOL DEFINITION Torque control required. Data beside it indicates specified torque. | Apply THREAD LOCK SUPER "1360" 99000-32130 faz JC Apply oil. Use engine oil unless otherwise specified. Apply SUZUKI SUPER GREASE “A, 99000-25010 ‘Apply THREAD LOCK SUPER _ “1303”. 99000-32030 Apply or use brake fluid. ‘Apply SUZUKI SILICONE GREASE. 99000-25100 Measure in voltage range. Apply SUZUKI MOLY PASTE. 99000-25140 Measure in resistance range. Apply SUZUKI BOND “1207B". 99000-31140 Measure in current range. ‘Apply SUZUKI BOND “1215”. 99000-31110 Use special tool. Ae a alae Apply THREAD LOCK “1342”. 99000-32050 ‘Use fork oil. '99000-99044.10GGENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE GENERAL PRECAUTIONS SUZUKI FX150... SERIAL NUMBER LOCATION .. FUEL AND ENGINE OIL RECOMMENDATIONS FUEL ... ENGINE OIL ... BRAKE FLUID .. FRONT FORK OIL BREAK-IN PROCEDURES .. SPECIFICATIONS DIMENSIONS AND DRY MASS ENGINE .. TRANSMISSION .. CHASSIS ELECTRICAL .. CAPACITIES ..4-1_ GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special atten- tion to the messages highlighted by these signal words. FUEGO Indicates a potential hazard that could result in death or injury. [A CAUTION | Indicates a potential hazard that could result in motorcycle damage. NOTE: Indicates special information to make maintenance easier or instructions clearer. Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addi. fion to the WARNINGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a particular service operation, ask @ more ‘experienced mechanic for advice. GENERAL PRECAUTIONS ~ Proper service and repair procedures are important for the safety of the service mecha and the safety and reliability of the motorcycl + When two or more persons work together, pay attention to the safety of each other. = When it is necessary to run the engine indoors, make sure that exhaust gas is forced out- doors. « When working with toxic or flammable materials, make sure that the area you work in is well ventilated and that you follow all of the manufacturer's instructions, * Never use gasoline as a cleaning solvent. * To avoid getting burned, do not touch the engine, engine have cooled. * After servicing the fuel, oil, exhaust or brake systems, check all of the lines and fitt related to the system for leaks. and exhaust system until theyGENERAL INFORMATION 1-2 A CAUTION * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent. + When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order. + Be sure to use special tools when instructed * Make sure that all parts used in reassembly are clean, Lubricate them when specified. * Use the specified lubricant, bond, or sealant. + When removing the battery, disconnect the negative cable first and then the positive cable. * When reconnecting the battery, connect the positive cable first and then the negative cable, and cover the positive terminal with the terminal cover. + When performing service to electrical parts, disconnect the battery negative cable unless the service procedure requires the battery power. + When tightening cylinder head and crankcase bolts and nuts, tighten the larger sizes first. Always tighten the bolts and nuts from the inside working out, in a crisscross pattern and to the specified tightening torque + Whenever you remove oil seals, gaskets, packing, O-rings, self-locking nuts, locking wash- ers, cotter pins, circlips, and certain other parts as specified, be sure to replace them new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces. » Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted. + Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is smeared with them. * After reassembling, check parts for tightness and proper operation. | * To protect the environment, do not unlawfully dispose of used motor oil and all other fluids, batteries, and tires. + To protect the earth's natural resources, properly dispose of used motorcycles and parts.3_ GENERAL INFORMATION. SUZUKI FX150 LEFT SIDE RIGHT SIDE + Difference between photographs and the actual motoreyeles depends on the markets. SERIAL NUMBER LOCATION The frame serial number or V.L.N. (Vehicle Identification Number) is stamped on the frame cross- bar. The engine serial number @ is located on the left side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts. FUEL AND ENGINE OIL RECOMMENDATIONS FUEL Use unleaded gasoline that is graded 85-95 octane or higher (Research Method). | aGENERAL INFORMATION ENGINE OIL Use only oils which are rated SF or SG under the API classi- fication. The recommended viscosity is SAE 10W/40. If SAE 10W/40 engine oil is not available, select an alternative according to the chart. mucricnane BRAKE FLUID specification and classification: DOT 4 IN) This motorcycle uses a glycol-based brake fluid. Do not use or mix different types of brake fluid such as silicone-based and petroleum-based fluids for refilling the system, otherwise seri ous damage will result to the brake system. Never use any brake fluid taken from old, used or unsealed containers. Never re-use brake fluid left over from the last servicing or which has been stored for a long period of time. FRONT FORK OIL Use fork oil #10. BREAK-IN PROCEDURES During manufacturing only the best possible materials are used and all machined parts are finished toa very high standard. 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. Refer to the following break-in engine speed recommendations. 4 © Keep to these break-in engine speed limits. Below 6 000 r/min. Below 9 000 r/min Over 1600 km: Below 12 500 r/min. © Upon reaching an odometer reading of 1 600 km you can subject the motorcycle to full throttle operation. However, do not exceed 12 500 r/min. at any time.41-5_ GENERAL INFORMATION {:S_GENERALINFORMATION SPECIFICATIONS DIMENSIONS neil pay MASS Overall length... Overall width Overall height, Wheelbase... Ground clearance. Dry mass. ENGINE Type ... Number of oylinder Bore Stroke.. Displacement. Compression rat Carburetor.. Air cleaner.. 10.71 MIKUNI BS29SS Polyurethane foam element Starter system... Electric and kick Lubrication system. Wet sump TRANSMISSION Clutch enn Wet, multi-plate type } Transmission. Gearshift pattern.. Primary reduction r Final reduction ratio. Gear ratios, 1st (low) 6-speed constant mesh sone. A28 (48/14) 3.000 (33/11) 2nd. 857 (26/14) 3rd... 1.368 (26/19) ath. 095 (23/21) Sth... 923 (24/26) 6th (top). (0.800 (20/25) Drive chain ..issen RK428HO, 132 linksGENERAL INFORMATION 1. SS}. $A _ENERAL INFORMATION 1-6 CHASSIS Front suspension Rear suspension Telescopic, coil spring, oil damped ‘Swingarm, coil spring, oil damped, spring pre-load, 4-way adjustable 35° (right & left) Steering angle... Caster Trail : Turning radius..... Front brake wn. Rear brake...... Front tire size. Rear tire size... ELECTRICAL Ignition type... Ignition timing.. -Disc brake Disc brake 80/90-17 44S, tube 100/90-17 56S, tube ..Electronic ignition (CDI) 9° B.T.D.C. at 1.500 r/t Spark plug. wu NGK CRBE or DENSO U24ESR-N Battery ..... 12V 14.4 kC (4 Ah)/10 HR Generator... Flywheel magneto Fuse. 20 Headlight 12.V 25/25 Wx2 -12V10W 2 V 18/5 W ZV 1.7 Wx2 12V1.7Wx2 2V 1.7 W Turn signal light. Brake light/tailligh Speedometer light wos. Turn signal indicator light. Neutral indicator light High beam indicator light 2V 1.7 W CAPACITIES Fuel tank, including reserve...... ee 5.0L reserve BAL Engine oil, oil change... 1.000 mi oil and filter change 1100 mi engine overhaul. 1.400 mi 5 Front fork oil. 101.5 ml. These specifications are subject to change without notice.PERIODIC MAINTENANCE CONTENTS ae PERIODIC MAINTENANCE SCHEDULE. 27 PERIODIC MAINTENANCE CHART. LUBRICATION POINTS.. MAINTENANCE AND TUNE-UP PROCEDURES. 23 EXHAUST PIPE BOLTS 23 AIR CLEANER . TAPPET CLEARANCE SPARK PLUG ... ENGINE OIL AND OIL FILTER .... FUEL HOSE .. CLUTCH CARBURETOR DRIVE CHAIN . BRAKES TIRES STEERING ......... FRONT FORK . REAR SUSPENSION .. CHASSIS BOLTS AND NUTS .. COMPRESSION PRESSURE CHECK .. COMPRESSION TEST PROCEDURE OIL PRESSURE CHECK .. OIL PRESSURE TEST PROCEDURE ..T } PERIODIC MAINTENANCE 241_PERIODIC MAINTENANCE 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. Maintenance intervals are ‘expressed in terms of kilometers and months, and are dependant on whichever comes first. NOTE: More frequent servicing may be performed on motorcycles that are used under severe conditions. PERIODIC MAINTENANCE CHART Interval km 7000 4000 8 000 Item: months 1 4 8 Exhaust pipe bolts T = it } Air cleaner = G c 4 Tappet clearance Inspect every 12 000 km. Spark plug = 1 R Engine oil R R R Engine oil filter, R = R Fuel hose = ! : Replace every four years Clutch 1 Engine idle speed | Throttle cable play Drive chain t t 1 U Clean and lubricate every 1000 km Brakes D 1 q = 1 1 Brake hose Replace every four years = I f Brake fluid | Replace every two years Tires = 1 Steering 1 = Front fork = = Rear suspension Chassis bolts and nuts al —|-F] = NOTE: Clean Replace T: Tighten Inspect and adjust, clean, lubricate or replace as necessaryPERIODIC MAINTENANCE 2-2 LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motor- cycle. Major lubrication points are indicated below. ABH Clutch lever holder Ef’ ciutch cable ABH Speedometer gearbox ABM Side-stand pivot and Drive chain spring hook ABH Broke lever holder state FEBM Storing stem bering ATH Broke pedal pivot and ADH Kick starter lever pivot footrest pivot NOTE: * Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime. + Lubricate exposed parts which are subject to rust, with a rust preventative spray, especially when- ever the motorcycle has been operated under wet or rainy conditions.errr Team caer Sanne ame ee 2-3 PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item in the Periodic Maintenance chart. EXHAUST PIPE BOLTS jhten initially at 1000 km (1 month) and every 8 000 km (8 months) thereafter. © Remove the lower fairings.(See p. 5-2.) Tighten the exhaust pipe bolts © and muffler mounting bolt © and nut @ to the specified torque. (©) Exhaust pipe bolt: 11 Nem (1.1 kg-m) Muffler mounting bolt and nut: 26 N-m(2.6 kg-m) AIR CLEANER Clean every 4.000 km (4 mont! If the air cleaner is clogged with dust, increase, resu a decrease in engine output and an increase in fuel consumption. Check and clean the air cleaner element in the following manner. ‘© Remove the fuel tank.(See p. 4-1.) Remove the air cleaner element holder O. ‘© Remove the air cleaner element holder by removing the bolt. ‘© Separate the air cleaner element @ and air cleaner ele- ment frame ©.¢ Fill a washing pan of a proper size with non-flammable cleaning solvent. Immerse the element in the cleaning solvent and wash it. ¢ Press the air cleaner element between the palms of both hands to remove the excess solvent: do not twist or wring the element or it will develop tears. ¢ Immerse the element in engine oil, and squeeze out the excess oil. The element should be wet but not dripping, ‘© Properly install the air cleaner element to the air cleaner element frame. ® Non-flammable cleaning solvent ® Engine oil © Face the arrow mark © on the air cleaner element holder towards the front side of the motorcycle. NOTE: When you clean the air cleaner element, drain any water from the air cleaner drain hose. [A CAUTION If driving under dusty conditions, clean the air cleaner lement more frequently. The surest way to acceler- ate engine wear is to use the engine without the ele- ment or to use a torn element. Make sure that the air cleaner is in good condition at all times. Life of the component! PERIODIC MAINTENANCE 2-42:5 PERIODIC MAINTENANCE TAPPET CLEARANCE Inspect every 12.000 km. INSPECTION Remove the fuel tank.(See p. 4-1.) © Disconnect the spark plug cap and remove the spark plug. © Remove the cylinder head cover. The tappet clearance specification is different for both intake and exhaust valves. Tappet clearance adjustment must be checked and adjusted, 1) at the time of periodic inspection, 2) when the valve mechanism is serviced, and 3) when the camshafts are removed for servicing. Tappet cl IN: 0.010-0.037 mm EX.: 0.030-0.057 mm yrance (when col NOTE: * The piston must be at top dead center (TDC) on the com- pression stroke in order to check or adjust the tappet clearance. » The tappet clearance should only be checked when the engine is cold. ‘© Remove the generator cover cap @ and valve timing inspection plug ®. © Rotate the crankshaft with a box wrench to set the piston at top dead center (TDC) on the compression stroke. (Rotate the crankshaft until the “T” line on the generator rotor is aligned with the center of the hole in the genera- tor cover.) @ Insert a thickness gauge between the tappet and the cam. If the clearance is out of specification, adjust it to specification as follows. 09900-20803: Thickness gaugePERIODIC MAINTENANCE _ 2-6 _—_—MA erin MAINTENANCE 2-6, ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim with a thicker or thinner shim. © Remove the intake or exhaust camshafts. (See p. 3-8.) ‘© Remove the tappet and shim by hand or with a magnet. (See p. 3-20.) © Check the numbers printed on the tappet shim. These numbers indicate the thickness of the tappet shim, as illustrated. © Select a replacement tappet shim that will provide the - proper clearance. Tappet shims are available in 21 sizes, QoS; ranging from 1,20 to 2.20 mm in increments of 0.05 mm. 1.70 mm Install the selected shim @ at the valve stem end, with the numbers facing towards the tappet. Be sure to mea- sure the shim with a micrometer to ensure that it is of the proper size. Refer to the tappet shim selection table for details. (qlune, ch oe] NOTE: * Be sure to apply engine oil to the top and bottom faces of the tappet shim. ® * When installing the tappet shim, make sure that the side with the numbers face towards the tappet. (A CAUTION) f ft Wal | Reinstall the camshafts as specified. (See pp. 3-53 ff. * After replacing the tappet shim and camshafts, rotate the | crankshaft so that the tappet is depressed fully (this will | squeeze out any oil trapped between the tappet shim | te and the tappet that could cause an incorrect measure- clearance again to make sure that it is within specifica- tion. © When installing the cylinder head cover, apply SUZUKI BOND NO.1207B to the cam end caps of the cylinder head cover gasket. "Gj 99000-31140: SUZUKI BOND NO.1207B ® Tighten the cylinder head cover bolts to specification in two stages. @) cylinder head cover bolt: Initial 10 Nem (1.0 kg-m) Final 14.Nem (1.4 kg-m) eeeuw 08° pesn oq. uw og" as ws wus waseig we wmero seine mt, = a sno exe [vz [ove so1m10t ervoroy u o28 wins sosaid yum uuinyo> eIUOA WY BUENeAP YEN wz | srz [ove | soz oo 960 “nis uns suosasd ainseovt i re farz [ore 140709 $1 3NION3,,‘90U8H80;9 184601 enseeyy 1 stheeinetes sien aeuliaen ol mod) wz [ave | ore [soz | oz 380-189 exe [sre fore] soz [ooz| ser ovo-9c0 wz [sre fore |s0z| 002 [seu | ov sc0=1c0 ee [siz fore [soz |ooe| sex [oer 010-890 az [ore [soz | ooz [sou | oes [see 390-190 ez] sve fore [soz [ove [sex [oor] sax [or 0-950 oz [vz [ove [202 | ooz [se | on | sev] oft [sre ss0=180 sve [ove | soz |ooe | sev | oon [sex foo] seu fore os0-8r0 eee [sv |ore [soz] coz] ser [oes | sex | oar] sce] oct | so [oon [as [ost sro-ro oz |srz [ove | soz [ooz [sex | oex | sex] oes [eeu [ors | sou oro-9e0 oz [siz [ore [soz] ooz [ses [on | se | oes | scx [ore [oon | ove srO-1e0 eee [sve [ove [soz [ove | se foo | se [oe | seu [ors | so: | 09% | os oco-970 eee [ore |svz [ore [soe [ooz [sox | o6+ [sex [oon |ecu [oan [ean | ons | eeu] ons aoe GaUINDIY INIWISNFOY ONSONVEYSTO 031410365 or0-0r0 ave [ore [soz [oow [oer [oes] se [ows [sce [ors [as [ove [sou [oss [srs [ore] se [oes [aes [ors 0-800 forz [soz [ooz [ser [oes | se | ov ser] ore [sou [ova] ovr [ose | ors [ors [ses | ors [eeu] ore 300-000 joce | svz| ore | soz] ooz| se | 06 | se | ov |ses fore | sox] ov | ss] os | sei | ov | sev] oe | sz] 07 um |_| ‘Rasa cae | siz | ore | soe | oor | sos | oo: | sor | oot | ses | cs | sor] oo: | sss} os: | sos | ons | seu | oes | ser | oer] y.0% eee (080-0082 1) ‘ON 13S WIHS LaddV 1. (x x x-00090-7682L)'ON WIHS LaddW1. [3YVLNIJ 318VL NOILOFIAS WIHS L3ddVL 8 2 Z z 3 & (INTAKE SIDE)PERIODIC MAINTENANCE 2-8 (EXHAUST SIDE) su 99° posn aa oon uns tus 0¢'4 as wie 080g oe er uw £0 = aoveie9 redde) eal oi Sane alana niece ove [Suz] ove SeE-tEL csunyoo : Feiuozu0Y UI 9215 WHYS 1UOSOId YIM UUINIOD JeONIAA UF BouEseR|D You pax | oe et fans unis wosdid ain oe [sre] ore [soe | oo so1=10% 1:10 $1 NINA. eDueIo( ode eneeoyy r= srz [ore| soz [ooz} sex 01-060 ez [stz| ore [soz] 007 [sex 350-160 LAE O61 SON. OL OH ove | stz | ove | soz | oz | s61 | ot 06'0~s8'0 ove [sre [ore [soz] ooz [a1] oon [ser svo-ieo wz [sve [ove [ove [ooe sa [owe oo0-060 eee | sre ore [soe [oe ser oon [ae sco=1c0 eee [sre | ore [soz [ooz [a0 [ose see foc eo-wwo ove [512 | ore| soz [ooz | se [oos [ees] ov facsf ors] ann s90-1w0 oc [sve [ore [soe [ooz [sou | oo [se [ows [acx ocx] sou fon 90-950 ozz [sre [ove [soe | oo | 61 [oes [aos [ows [scx [ors] sou] oot [aor ss0-is0 oe [sve [ore [202 [o0z | 61 [osx] ses [ows [sex forr} sou fons fees fost os0-9r6 ove [sv [ove [soz [ooz [sev ove |se [ows [exe [ors |oor] oon fans] ons [ari sro-iw0 ove [ave [ove [soz [oz [sen [ons | oa [ov fact [ors [anu [oor] oa [ors Pera Porn ovo-9e0 oe Joce [sz [ore [sox [oor [sex [oon [sos [oan [zr | oun sot] cos fern] ont forf or fact so-10 3UINO3Y INSWISNTOY ONONVUVTIO GalsIO3as oe0-080 063 [30% [ovis | 9c Tocs [oon [oon [55% [ove [ors [ors] oea [ons [eeu [or ero-sro sau [on [seu [orn [so [oma fos [ors ers [ore sea] orc] sea | ore wo-ore ot [sex [ors [so Joon [esr fos [rx [ors [sex Jor] sex for s00-500 361] 06% |se% | oes far Joes | so | oo | se owt | se] oF | se | oo fs on isnt somewvn | rr "Baan so. Joes | sur | ozs | soi] oot } ss | ost | sei | on | ses | oct | set | oct | yl “ (0780-00821) ‘ON 13S WIHS 13ddv1 (X x x -00980-7682 L)'ON WIHS LaddVL [LSAVHXa] 318VL NOILD373S WIHS LaddVL2-9 PERIODIC MAINTENANCE SPARK PLUG Inspect every 4000 km (4 months). | Repl 10 kmn (8 months). | Neglecting the spark plug eventually leads to difficult start- ing and poor engine performance. If the spark plug is used for a long period, the electrode gradually burns away and carbon builds up along the inside of the spark plug. In accordance with the Periodic Maintenance chart, the spark plug should be inspected, cleaned and regapped at the rec- ‘ommended intervals. ‘@ Romove the fuel tank. (See p. 4-1.) ® Disconnect the spark plug cap and remove the spark plug ‘¢ Carbon deposits on the spark plug will prevent good sparking and may cause the engine to misfire. Be sure to clean the carbon deposits off periodically. « ifthe center electrode is fairly worn down, the spark plug should be replaced and the spark plug gap set to specifi- cation using a thickness gauge. (09900-20803: Thickness gauge Spark plug gap: 0.7-0.8 mm. © Check the spark plug for burns. If any abnormalities are found, replace the spark plug as indicated below. NGK DENSO Remarks ifthe standard spark plug is apt to get wet, replace ore U22ESR-N | with one of these spark plugs. CREE U24ESR-N | Standard = 1B If the standard spark plug Cree ustesr.n | ‘8 2ptto overheat, replace with one of these spark plugs. @ Tighten the spark plug to the specified torque using the special tool. 09930-10121: Spark plug socket wrench set © spark plu: 211 Nem (1.1 kg-m) [A CAUTION] Confirm the thread size and reach when replacing the spark plug. If the reach is too short, carbon will be deposited on the screw portion of the plug hole and engine damage may result.PERIODIC MAINTENANCE 2-10 ENGINE OIL AND OIL FILTER (ENGINE OIL) Replace initially at 1000 km (1 month) and every 4.000 km (4 months) thereafter. {OIL FILTER) Replace initially at 1000 km (1 month) and every 8 000 km (8 months) thereafter. The engine oil should be changed while the engine warm. Gil filter replacement at the above intervals, should be done together with the engine oil change. ENGINE OIL REPLACEMENT © Keep the motorcycle upright. © Place an oil pan below the engine, and drain the engine oil by removing the oil drain plug © and filler cap @, ighten the oil drain plug @ to the specified torque, and pour new oil through the oil filler. When performing an oil change (without oil filter replacement), the engine will hold about 1.0 L of oil. Use SF or SG classified (API) engine oil with a viscosity rating of 10W/40 (SAE), ©) oi drain plug: 48/N+1 (1.8 kg-m) © Install the oil filler cap. © Start up the engine and allow it to run for several sec- onds at idling speed. © Turn off the engine and wait about one minute, then check the oil level through the inspection window ©. If the level is below the “F” mark, add oil to the proper level. OIL FILTER REPLACEMENT Drain the engine oil as described in the engine oil replacement procedure. © Remove the oil filter cap © by removing the bolts. ‘© Remove the oil filter @ and install a new one. © Install the oil filter cap © and tighten the bolts securely.}1_ PERIODIC MAINTENANCE. NOTE: yi. Before installing the new oil filter and oil filter cap, make @ sure that the spring @ and new O-rings (@, @) are installed correctly. ‘© Add new engine oil and check the oil level as described in the engine oil replacement procedure. Oil viscosity and classification: 10W/40 (SAE) / SF or SG (API) NECESSARY AMOUNT OF ENGINE OIL Oil change : 1000 ml Oil and filter change : 1 100 ml Engine overhaul : 1 400 ml FUEL HOSE mecpre wars Tt BE Inspect every 4000 km (4 months). Replace every four years. CLUTCH Inspect initially at 1000 km (1 month) and every 4.000 km (4 months). [600k oe © Loosen the locknut @ and turn the adjuster @ fully in. ‘© Loosen the locknut @ and turn the adjuster @ until the clutch lever play @ is within specification. Clutch lever play @: 10-15 mm © Tighten the locknuts (©, ®).PERIODIC MAINTENANCE _2-12 CARBURETOR Inspect initially at 1000 km (1 month) and every 4.000 km (4 months) thereafter. ENGINE IDLE SPEED © Adjust the throttle cable play. (See p. 2-12.) ‘© Warm up the engine, NOTE: Make this adjustment when the engine is hot. Connect an electric tachometer to the high-tension cord. ¢ Start the engine, turn the throttle stop screw and set the engine idle speed between 1360 and 1550 r/min, 09900-26006: Tachometer idle speed: 1 4504100 r/min. THROTTLE CABLE PLAY Throttle cable play @ should be 3-6 mm as measured at the throttle grip when turning the throttle grip lightly. If the throttle cable play @ is incorrect, adjust it as follows: © Loosen the locknut © and turn the adjuster @ in or out until the specified play is obtained. ighten the locknut @ while holding the adjuster ©. Throttle cable play ®: 3-6 mm PROGINS After the adjustment is completed, check that handle- bar movement does not raise the engine idle speed and that the throttle grip returns smoothly and auto- matically.13 PERIODIC MAINTENANCE DRIVE CHAIN Inspect initially at 1000 km (1 month) and every 4,000 km (4 months) thereafter. Clean and lubricate every 1000 km. Visually inspect the drive chain for the possible defects listed below. Loose pins | * Damaged rollers * Rusted links » Excessive wear » Kinked or binding links * Missing O-ring seals * Twisted or seized links If any defects are found, the drive chain must be replaced. A CAUTION) ‘The standard drive chain is RK428HO. SUZUKI recom- mends to use this standard drive chain as a replace- ment. CHECKING AND ADJUSTING © Loosen the rear axle nut @ and chain adjusting locknuts @. ‘¢ Tense the drive chain fully by turning both chain adjuster bolts @. ‘© Count out 21 pins (20-pitch) on the chain measure the distance between the two points. If the distance exceeds the service limit, the chain must be replaced, Drive chain 20-pitch length: 255.5 mm NOTE: When replacing the drive chain, replace the drive chain and sprockets as a set.PERIODIC MAINTENANCE 2-14 ¢ Loosen or tighten both chain adjuster bolts @ until the chain has 20-30 mm of slack at the middle of the chain between the engine and rear sprockets as shown. The reference marks @ on both chain adjusters must be at the same position on the scale to ensure that the front and rear wheels are correctly aligned. @ Tighten the rear axle nut @ after adjusting the drive chain, and then tighten the chain adjusting locknuts @. (©) Rear axle nut: 72 Nem (7.2 kg-m) Drive chain slack: 20-30 mm CLEANING AND LUBRICATING © Clean the drive chain with kerosine. If the drive chain tends to rust quickly, the intervals must be shortened, A CAUTION Do not use trichloroethylene, gasoline or any similar solvent. ‘These fluids have too great a dissolving power for this chain and they can damage the O-rings. Use only ker- osine to clean the drive ch © After cleaning and drying the chain, oil it with a heavy- weight engine oil. [A CAUTION 7 Do not use any oil sold commercially as “drive chain type of oil can damage the O-rings.eer ————“‘—~— PERIODIC MAINTENANCE BRAKES (BRAKE) Inspect initially at 1000 km (1 month) and every 4.000 km (4 months) thereafter (BRAKE HOSE AND BRAKE FLUID) Inspect every 4.000 km (4 months). Replace hoses every four years. lace fluid every two years. BRAKE FLUID LEVEL ‘e Keep the motoroycle upright and place the handlebars straight. © Check the brake fluid level by observing the lower limit line on the front and rear brake fluid reservoirs. © When the brake fluid level is below the lower limit line, replenish with brake fluid that meets the following speci- fication, B Specific FOEGNINS The brake system of this motorcycle is glycol-based brake fluid. Do not use or mix dif types of fluid such as silicone-based and petroleum- based fluids. Do not use any brake fluid taken from ‘old, used or unsealed containers. Never re-use brake fluid left over from the last servi stored for a long period of tim + Brake fluid, if it leaks, will interfere with safe run- ning and immediately discolor painted surfaces. Check the brake hoses and hose joints for cracks and oi n and classification: DOT 4 iiBRAKE PADS The extent of brake pad wear can be checked by observing the grooved limit line © on the pad. When the wear exceeds the grooved limit line, replace the pads with new ones. (See pp. 5-35 and -43.) [A CAUTION Replace the brake pads as a set, otherwise bral performance will be adversely affected. AIR BLEEDING THE BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the brake caliper. The presence of air is indicated by “sponginess” of the brake lever or brake pedal and also by lack of braking force. Considering the danger to which such trapped air exposes the machine and rider, it is essential 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: ¢ Fill the master cylinder reservoir to the top of the inspec- tion window. Replace the reservoir cap to prevent dirt from entering. © Attach a hose to the air bleeder valve, and insert the free end of the hose into a receptacle. © Front brake: Bleed air from the brake system. © Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it. Loosen the air bleeder valve by turning it a 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 air bleeder valve, pump and squeeze the lever, and open the valve. Repeat this process until the fluid flowing into the Feceptacle no longer contains air bubbles. PERIODIC MAINTENANCE 2-162-47 PERIODIC MAINTENANCE NOTE: While bleeding the brake system, replenish the brake fluid in the reservoir as necessary. Make sure that there is always some fluid visible in the reservoir. © Close the air bleeder valve, and disconnect the hose. Fill the reservoir with brake fluid to the top of the inspection window. (®) Air bleeder vaive: 7.5 N-m (0.75 kg-m) © Rear brake: The only front and rear brakes actuated by a pedal. ference between bleeding the that the rear master cylinder is BRAKE PEDAL HEIGHT @ Loosen the locknut ©. © Turn the push rod @ until the brake pedal is 50 mm ® below the top of the footrest. ¢ Tighten the locknut © securely. Brake pedal height @: 50 mm REAR BRAKE LIGHT SWITCH Adjust the rear brake light switch so that the brake light will come on just before pressure is felt when the brake pedal is depressed.ERIODIC MAINTENANCE 2-18 TIRES Inspect every 4 000 km (4 months). TIRE TREAD CONDITION Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a danger- ous situation. It is highly recommended to replace a tire when the remaining depth of the tire tread reaches the fol- cation. 09900-20805: Tire depth gauge Tire tread depth limit Front: 1.6 mm Rear: 2.0mm TIRE PRESSURE If the tire pressure is too high or too low, steering will be adversely affected and tire wear will increase, Therefore, maintain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows. COLDINFLATION | SOLDRIDING | DUALRIDING TIRE PRESSURE [~KPa_| kgfem® | kpa | kglom’ [__ FRONT ms | 175 | 175 | 1.75 REAR 200 | 200 | 225 | 225 [A CAUTION] | The standard tre fitted on this motoroyole Is @ €0/90- 17 445 for the front and a 100/90-17 55S for the rear. The use of tires other than those specified may cause instability. Its highly recommended to use the speci- fi19 _ PERIODIC MAINTENANCE. STEERING inspect initially at 1000 km (1 month) and every 8000 km (8 months) thereafter. ‘The steering should be adjusted properly for smooth turn- ing of the handlebars and safe operation. Overtight steer- ing prevents smooth turning of the handlebars and too loose steering will cause poor stability. Check that there is no play in the front fork. Support the motorcycle so that the front wheel is off the ground. With the wheel facing straight ahead, grasp the lower fork tubes near the axle and pull forward. If play is found, readjust the steering. (See p. 5- 20.) FRONT FORK Inspect every 8 000 km (8 months). Inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defec- tive parts, if necessary. (See pp. 5-9 ff..) REAR SUSPENSION Inspect every 8 000 km (8 months). Inspect the rear shock absorber for oil leakage and dam- age. Replace any defective parts, if necessary.PERIODIC MAINTENANCE _ 2-20 CHASSIS BOLTS AND NUTS Tighten initially at 1000 km (1 month) and every 4.000 km (4 months) thereafter Cheok that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-21 for the locations of the following nuts and bolts on the motorcycle.) ITEM Nem kg-m | ® Front axle nut 53 53 | ® Steering stem head nut 90 9.0 | @® Handlebar mounting bolt 50 5.0 @ Handlebar mounting nut 60 "6.0 © Front fork cap bolt 23 23 © Front fork upper clamp bolt 23 23 © Front fork lower clamp bott 33 33 Front brake master cylinder bolt 10 10 Brake hose union bolt (front & rear) 23 23 ® Front brake caliper mounting bolt 26 26 @ Brake air bleeder valve (front & rear) 75 0.75 ® Front brake pad mounting bolt 18 18 @® Front brake disc bolt Pry 23 @ Rear axle nut 72 72 ® Rear sprocket nut 23 23 @ Engine mounting nut 66 66 ® Engine mounting bolt 31 31 | @ Rear brake caliper mounting bolt 39 39 | @ Rear brake pad mounting bolt 18 18 @ Rear brake disc bolt 23 23 @ Rear brake master cylinder bolt 23 23 @ Rear brake master cylinder rod locknut 18 18 | @ Front footrest bracket bolt 23 23 | @ Swingarm pivot nut ee 78 78 | @ Rear shock absorber nut (upper) 54 5.4 @ Rear shock absorber bolt (lower) 45 452:21 PERIODIC MAINTENANCEPERIODIC MAINTENANCE 2-22 COMPRESSION PRESSURE CHECK The compression pressure reading of the cylinder is a good indicator of its internal condition, The decision to overhaul the cylinder is often based on the results of a compression test. Periodic maintenance records kept at your dealership should include compression readings for each mainte- nance service. COMPRESSION PRESSURE SPECIFICATION Standard _ Limit 1 450 kPa 1100 kPa (14.5 kg/om?) (11 kg/em2) Low compression pressure car + Excessively worn cylinder walls * Worn piston or piston rings * Piston rings stuck in grooves * Poor valve seating + Ruptured or otherwise defective cylinder head gasket icate any of the following condi COMPRESSION TEST PROCEDURE NOTE: * Before testing the engine for compression pressure, make sure that the cylinder head bolts are tightened to the specified torque values and the valves are properly adjusted. + Have the engine warmed-up before testing. + Make sure that the battery is fully-charged. Remove the related parts and test the compression pres- sure in the following manner. © Remove the fuel tank. (See p. 4-1.) ‘© Remove the spark plug. * Install the compression gauge and adaptor in the spark plug hole. Make sure that the connection is tight. * Keep the throttle grip in the fully opened position. © Press the starter button and crank the engine for a few seconds. Record the maximum gauge reading as the cy!- inder compression, (B® 09915-64510: Compression gauge 09913-10750: Adaptor(ODIC MAINTENANCE 2.23 _ PER OIL PRESSURE CHECK Check the engine oil pressure periodically. This will give a good in moving parts. | OIL PRESSURE SPECIFICATION tion of the condition of the ‘Above 30 kPa (0.3 kg/em?) at 3 000 r/min., Oil temp. at 60°C Below 70 kPa (0.7 kg/m? ) Ifthe oil pressure is lower or higher than the specification, the following causes may be considered. LOW OIL PRESSURE Clogged oil filter Oil leakage from the oil passage Damaged O-ring Defective oil pump Combination of the above items HIGH OIL PRESSURE + Engine oil viscosity is too high * Clogged oil passage * Combination of the above items OIL PRESSURE TEST PROCEDURE Check the oil pressure in the following manner. @ Remove the lower fairings.(See p. 5-2.) « Install the oil pressure gauge and adaptor in the position as shown. Connect an electric tachometer to the high-tension cord. ‘© Warm up the engine as follows: Summer 10 min. at 2.000 r/min. Winter 20 min. at 2 000 r/min. © After warm up, increase the engine speed to 3.000 1/ min, and read the oil pressure gauge. (GB 09915-74510: Oil pressure gauge 09915-72410: Adaptor 09900-26006: TachometerCONTENTS ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE ... ENGINE REMOVAL AND REINSTALLATION REMOVAL .. REINSTALLATION ENGINE DISASSEMBLY . ENGINE COMPONENTS INSPECTION AND SERVICE BEARINGS .. CYLINDER HEA CAMSHAFT .... CAM CHAIN TENSION ADJUSTER CYLINDER .. PISTON AND PISTON PIN. CRANKSHAFT AND CONROD . BALANCER SHAFT AND CRANKSHAFT DRIVEN GEARS STARTER CLUTCH AND STARTER DRIVEN GEAR BEARING TRANSMISSION ... 3-37 PRIMARY DRIVE GEARS 3-39 CLUTCH ENGINE REASSEMBLY CRANKSHAFT .... BALANCER SHAFT KICK STARTER ... GEARSHIFT CAM AND GEARSHIFT FORKS GEAR POSITION SWITCH . 3-44 ENGINE SPROCKET SPACER 3-44 CAM CHAIN, CAM CHAIN TENSIONER GUIDE AND GENERATOR ROTOR .. OIL JET ... BALANCER SHAFT BOLT OIL PUMP AND PRIMARY GEARSHIFT SHAFT AND RELATION PARTS CLUTCH .. PISTON AND PISTON RING .. CYLINDER ... CYLINDER HEAD CAMSHAFT GENERATOR COVER ...31_ ENGINE ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE The parts listed below can be removed and reinstalled wi ;thout removing the engine from the frame. Refer to the page listed in each section for removal and reinstallation instructions. ENGINE CENTER Muffler. Carburetor... Cam chain tension ad Cylinder head cover. Camshaft Cylinder hea Cylinder. Piston. Starter moto! ENGINE LEFT SIDE See page Engine sprocket. 3-7 and -5 Generator cover 3-11 and -87 Stator coi Pick-up coil... Starter idle gear. Generator rotor . Cam chain Gear position switch 3-13 and -44 -13 and -44 NOTE: juster.. See page ENGINE RIGHT SIDE See page Clutch cover. -9 and -50 Clutch... 3-10 and -48 Primary drive gears... ..3-12 and -46 Oil pump..... 13-12 and -45 Gearshift cam on 3-14 and -43 When removing the cylinder head, remove the rear engine mounting lower bolt other relation parts, and then lift the front of engine after loosening the rear engine mounting upper nut.ENGINE REMOVAL AND REINSTALLATION REMOVAL ¢ Remove the side covers, lower covers and frame covers. (See pp. 5-2.) Remove the carburetor. (See p. 4-8.) © Drain the engine oil. (See p. 2-10.) © Disconnect the battery © lead wire. @ Remove the exhaust pipe bolts () and muffler mounting bolts (@, @) and nut. ® Remove the clutch release arm @ along with the clutch cable ©. ® Disconnect the crankcase breather hose ©.3-3_ ENGINE © Disconnect the starter motor lead wire ©. © Disconnect the spark plug cap ©. © Disconnect the clamp ©. © Disconnect the gear position switch couplers @, pick-up coil coupler © and stator coil coupler ©. © Disconnect the clamp ©. © Disconnect the engine ground coupler ®. @ Remove the oil cooler and O-rings by removing the mounting bolts.ENGINE © Remove the gearshift lever © and engine sprocket cover ©. « Flatten the lock washer and remove the engine sprocket nut ©. NOTE: When loosening the engine sprocket nut, depress the brake pedal. © Remove the engine sprocket @. ‘© Remove the engine mounting bolts and nuts. * Remove the engine.REINSTALLATION Reinstall the engine in the reverse order of engine removal. © Install the engine mounting bolts and apply THREAD LOCK SUPER "1303" to the threads of the three bolts. © Tighten the nuts ® and bolt @ to the specified torque. +0& 99000-32030: THREAD LOCK SUPER “1303” (Engine mounting nut: 66 N-m (6.6 kg-m) bolt : 31 Nem (3.1 kg-m) © Loosen the rear axle nut and drive chain adjusting nuts. ‘© When installing the engine sprocket, face the tapered portion @) of the sprocket damper towards the crank- case. ¢ Install the drive chain. © Tighten the engine sprocket nut to the specified torque. {© Engine sprocket nut: 90 N-m (9.0 kg-m) NOTE: When tightening the engine sprocket nut, depress the brake pedal. © Bend the lock washer securely.all ENGINE 3-6 ¢ Tighten the exhaust pipe bolts @ and muffler mounting bolt @ and nut @ to the specified torque. (©) Exhaust pipe bolt: 11 Nem (1.1 kg-m) Muffler mounting bolt and nut: 26 Nem (2.6 kg-m) © After remounting the engine, the following adjustments are necessary. * Throttle cable play. * Engine idle speed * Drive chain. Se p. 2-12. See p. 2-12. See pp. 2-13 f. * Brake pedal height ‘See p. 2-17. ACAUTION] Check the wire, cable and hose routing. (See pp. 7-10 i) '* Pour 1400 ml of SAE 10W/40 engine oil, graded SF or SG, into the engine after overhauling it. Start up the engine and allow it run for several seconds at idle speed. Stop the engine, wait approximately one minute and check the oil level. If the level is below the “L” line, add Oil until the level reaches the “F" line. (See p. 2-10.)ee ee ~~ 3-7_ ENGINE ENGINE DISASSEMBLY The procedure for engine disassembly is sequentially explained in the following steps. ‘© Remove the kick starter lever ©. ‘@ Remove the cylinder head cover @. ‘© Remove the spark plug. ‘© Remove the valve timing inspection plug @ and genera- tor cover cap @- © Rotate the crankshaft and align the “T" line on the gener- ator rotor with the center of the hole in the generator cover. © Remove the cam chain tension adjuster cap and insert a flat-head screwdriver into the slotted end of the cam chain tension adjuster. Turn the screwdriver clockwise to lock the spring tension. ‘© Remove the cam chain tension adjuster.ENGINE 38 @ Remove the camshaft holders. © Remove the intake © and exhaust @ camshatts. ¢ Remove the cam chain guide ®. © Remove the engine oil pipe @. © Remove the cylinder head © by removing the bolts and nuts. * Remove the cylinder head gasket. * Remove the cylinder ® by removing the cylinder base nuts,eee _———te 39 ENGINE ‘© Remove the cylinder gasket. © Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into the crankcase. Then, remove the piston pin circlip with long-nose pliers. ‘© Remove the piston pin using the special tools. 09910-34510: Piston pin puller ‘© Remove the piston. © Remove the starter motor @. © Remove the clutch cover ®. | © While holding the generator rotor nut, remove the clutch spring mounting bolts in a crisscross pattern, and remove the clutch springs and clutch pressure plate @.ENGINE 3-10 ‘® Remove the clutch release rack @ and clutch release bearing @ from the clutch pressure plate. ‘ Remove the clutch drive and driven plates. © Flatten the lock washer @, and remove the clutch sleeve hub nut using the special tool. (09920-53740: Clutch sleeve hub holder ‘© Remove the thrust washer © and primary driven gear assembly ©. ‘* Remove the spacer © and washer© Remove the gearshift shaft © and washer @. © Remove the gearshift cam plate @ by removing the gearshift cam plate bolt @. ‘© Remove the gearshift cam stopper arm @) by removing the gearshift cam stopper arm shaft and nut. © Remove the generator cover ©. ‘© Remove the stator coil ® and pick-up coil ©. © Remove the spacer @, shaft @, starter idle gear @ and oil sump filter ®.‘@ Remove the primary drive gear nut © using the special tool. (09930-44512: Rotor holder NOTE: The primary drive gear nut © has left-hand threads. ¢ Remove the washers @ and primary drive gears @. ‘ Remove the key ® and oil pump drive gear ©. ¢ Remove the E-ring © and oil pump driven gear @. ¢ Remove the spacer ®, pin @ and oil pump @. Remove the balancer shaft bolt and washer using the special tool. (3) 09930-44512: Rotor holder ‘® Remove the generator rotor nut using the special tool. 09930-44512: Rotor holder343_ ENGINE | © Remove the generator rotor @ using the special tool. 1 (@®) 09930-34951; Rotor remover © Remove the generator rotor key @. © Remove the cam chain @. ‘© Remove the cam chain tensioner guide @. ¢ Remove the oil seal retainer © and engine sprocket spacer ©. ‘© Remove the gear position switch @. ‘® Remove the gear position switch contact ©, spring © and O-ring ®. ‘© Remove the crankcase bolts.il ‘© Separate the right and left crankcases using the special tool. (B) 09920-13120: Crankease separator ¢ Remove the gearshift fork shafts ©, gearshift forks @ and gearshift cam ©. @ Remove the transmission. ‘¢ Remove the washer ® and kick starter drive gear ©). * Remove the kick starter guide bolts and kick starter 2 oD, shaft © along with the kick starter ©.345 _ ENGINE @ Remove the crankshaft driven gears along with the bal- ancer shaft, | II © Remove the crankshaft using the special tool. (09920-13120: Crankease separatorall ENGINE COMPONENTS INSPECTION AND SERVICE BEARINGS BEARING INSPECTION While the bearing is in the crankcase, rotate its inner race and check to see that it turns smoothly. If it does not turn fo quietly and smoothly, or if there are signs of any abnormal- ities, the bearing is defective and must be replaced as fol- lows. LEFT DRIVESHAFT BEARING ‘@ Remove the bearing retainer ©. '® Remove the oil seal using the special tool. (09913-50121: Oil seal remover ;AUTION | The removed oil seal should be replaced with a new one. ‘© Remove the washer @. ‘© Remove the left driveshaft bearing using the special tool. (09922-55131: Countershaft remover [A CAUTION] The removed be: ‘ong ig should be replaced with a new * Install the left driveshaft bearing using the special tool. (3 09913-75810: Bearing instalENGINE @ Install the oil seal using the special tool. © Apply a small quantity of SUZUKI SUPER GREASE “A” to the lip of the oil seal. 5654199000-25010: SUZUKI SUPER GREASE “A” 09922-55131: Countershaft remover ¢ Tighten the bearing retainer screws to the specified torque. (7) Bearing retainer screw: 8.5 N-m (0.85 kg-m) RIGHT DRIVESHAFT BEARING ‘@ Remove the right driveshaft bearing using the special tool. (09943-88211: Pinion bearing installer [A CAUTION The removed bearing should ° replaced wit @ Install the right driveshaft bearing using the special tool. (GB) 09922-55131: Countershaft remover LEFT COUNTERSHAFT BEARING ‘© Remove the left countershaft bearing using the special tools. 09921-20210: Bearing remover 09930-30102: ing hammer [A CAUTION] The removed bearing should be replaced with a new one.ENGINE 3-418 @ Install the left countershaft bearing using the special tool. (GB) 09913-75821: Bearing installer attachment RIGHT COUNTERSHAFT BEARING ‘¢ Remove the bearing retainer ©. ¢ Remove the right countershaft bearing using the special tool. (GB) 09913-75821: Bearing installer attachment [A CAUTION | The removed bearing should be replaced with a new one. ¢ Install the right countershaft bearing using the special tool. 09913-76010: Bearing installer * Align the recesses © on the bearing retainer with the lug @ on the right crankcase. * Tighten the bearing retainer screws to the specified torque. (©) Bearing retainer screw: 8.5 N-m (0.85 kg-m) CRANKSHAFT BEARINGS ® Remove the left and right crankshaft bearings using the ‘special tool. (By 09913-75810: Bearing installer [A CAUTION) The removed bearings should be replaced with new ones.eee ——te 349_ ENGINE ¢ Install the left and right crankshaft bearings using the special tool. 09913-75510: Bearing installer BALANCER SHAFT BEARINGS @ Remove the left balancer shaft bearing O. [A CAUTION] CAUTION ‘The removed bearing should be replaced with a new one. ‘© Remove the right balancer shaft bearing using the spe- cial tool. (09913-75821: Bearing installer attachment ‘A CAUTION) ‘The removed bearing should be replaced with a new one. «© Install the left and right balancer shaft bearings using the special tool. (GB) 09913-76010: Bearing installer GEARSHIFT CAM BEARING ‘© Remove the bearing retainer ©. @ Remove the gearshift cam bearing using the special tool. (03913-75821: Bearing installer attachment ON} ‘The removed bearing should be replaced wi one.ENGINE 320 ¢@ Install the gearshift cam bearing using the special tool. () 03913-76010: Bearing installer @ Tighten the bearing retainer screws to the specified torque. {© Bearing retainer screw: 8.5 N-m (0.85 kg-m) CYLINDER HEAD DISASSEMBLY © Remove the intake pipe @. [A CAUTION The removed O-ring @ should be replaced with a new one. * Remove the tappets @ and shims @ by hand or with a magnet.ee —Ss 3-21 _ ENGINE @ Compress the valve spring and remove the valve cotters @ from the valve stem using the special tools. (By 09916-14510: Valve lifter (09916-14530: Valve lifter attachment 09916-84511: Tweezers @ Remove the valve spring retainer @, valve spring @ and valve spring seat @. ‘© Remove the valve © from the combustion chamber side. CYLINDER HEAD DISTORTION Decarbonize the combustion chamber. Check the gasket surface of the cylinder head for distortion using a straightedge and thickness gauge. Take clearance readings at several places. If readings exceed the service limit, replace the cylinder head. B® 02900-20803: Thickness gauge Service Limit: 0.05 mm VALVE FACE WEAR ‘The thickness of the valve face decreases as the face wears. Visually inspect each valve face for wear and replace any valve with an abnormally worn face. Measure the valve face thickness ©. If it is out of specification, replace the valve with a new one. 09900-20101: Vernier calipers Service Limit: 0.5 mmENGINE 3.22 VALVE STEM RUNOUT | Support the valve using V-blocks, as shown, and measure its runout with the dial gauge. If the runout exceeds the limit, replace the valve. (GB) 03900-20701: Magnetic stand 09900-20606: Dial gauge (1/100 mm) 09900-21304: V-block set (100 mm) Service Limit: 0.05 mm VALVE HEAD RADIAL RUNOUT Place the dial gauge at a right angle to the valve head face and measure the valve head radial runout. IFit measures more than the servi it, replace the valve. (09900-20701: Magnetic stand 09900-20608 gauge (1/100 mm) 09900-21304: V-block set (100 mm) Service 0.03 mm VALVE STEM DEFLECTION Lift the valve about 10 mm from the valve seat. Measure the valve stem deflection in two directions, “X" and “Y", perpendicular to each other. Position the dial gauge as shown. If the deflection exceeds the service limit, then determine whether the valve or the guide should be replaced with a new one. (65 09900-20701: Magnetic stand (09900-20606: Dial gauge (1/100 mm) Service Limit Intake and exhaust valves: 0.35 mm. VALVE STEM WEAR Measure the valve stem O.D. using the micrometer. If it is ut of specification, replace the valve with a new one. If the valve stem 0.D. is within specification but the valve stem deflection is not, replace the valve guide. After replacing the valve or valve guide, recheck the clearance. (3 09900-20205: Micrometer (0-25 mm) | Standard Valve stem 0.D. IN.: 4.475-4.490 mm EX.: 4.455-4.470 mm Note: If valve guides have to be replaced, refer to the valve guide ] Servicing steps below.__—_———— =~=—SCS=«# 323 ENGINE VALVE GUIDE SERVICE @ Remove the valve guide using the special tool. (09916-43210: Valve guide installer NOTE: » Discard the removed valve guide subassemblies. * Only oversized valve guides are available as replacement parts. © Re-finish the valve guide hole in the cylinder head using the special tools. 09916-34580: Valve guide reamer (10.8 mm) 09916-34542: Handle NOTE: Insert the reamer from the combustion chamber side and always turn the reamer handle clockwise. Install a ring onto each valve guide. ‘© Oil the stem hole of each valve guide and drive the guide into the guide hole using the special tool (00916-43210: Valve guide installer ‘ACAUTION] Be sure to use a new valve guide ring and valve guide. ¢ After installing the valve guides, re-finish their guiding bores using the special tools. Be sure to clean and oil the guides after reaming. (B) 09916-33210: Valve guide reamer (4.5 mm) 09916-34542: Handle VALVE SEAT WIDTH © Coat the valve seat uniformly with Prussian blue. Install the valve and attach a valve lapper onto it. Tap the coated seat with the valve face in a rotating manner, in order to obtain a clear impression of the seating contact.ENGINE 3-24 ‘© The ring-like dye impression left on the valve face must be continuous without any breaks. In addition, the width of the dye ring, which is the valve seat width, must be within the following specification: Standard Valve seat width W: 0.9-1.1 mm Ifthe valve seat is out of specification, re-cut the seat. VALVE SEAT SERVICE The valve seats for both intake and exhaust valves are machined to four different angles. (The seat contact surface is cut 45°.) INTAKE SIDE EXHAUST SIDE 45° N-131 45° N-131 30° | N-126 15° N-130 a (09916-21110: vaive seat cutter set 09916-24410: Valve seat cutter (N-111) 09916-24460: Valve seat cutter (N-130) 09916-24470: Valve seat cutter (N-131) 09916-20630: Valve seat cutter (N-126) 09916-20640: Solid pilot (N-100-4.5) NOTE: The valve seat contact area must be inspected after each cut. * When installing the solid pilot ©, rotate it slightly. Seat the pilot snugly. Install the 45° cutter, attachment and T- handle. * Using the 45° cutter, descale and clean up the seat. Rotate the cutter one or two turns. * Measure the vaive seat width after every cut. if the valve seat is pitted or burned, use the 45° cutter to condition the seat some more. NOTE: Cut only the minimum amount necessary from the seat to avoid having to replace the tappet shim. lf the contact area is too high on the valve, or if it is too Wide, use the 15° cutter (for the exhaust side) and the 30°/ 680° cutters (for the intake side) to lower and narrow the Contact area. INTAKE EXHAUST3-25_ ENGINE If the contact area is too low or too narrow, use the 45° cut- ‘Contact area to0 high and too wide ter to raise and widen the contact area. ee esca stsatea @ After the desired seat position and width is achieved, use the 45° cutter very lightly to clean up any burrs caused by the previous cutting operations. [A CAUTION| DO NOT use lapping compound after the final cut is made. The finished valve seat should have a velvety @ smooth finish and not a highly polished or shiny fin- ish. This will provide a soft surface for the final seat- ‘Contadt area too low and too narn ing of the valve which will occur during the first few ecoanen " seconds of engine operation. @ Clean and assemble the head and valve components. Fill the intake and exhaust ports with gasoline to check for leaks. If any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from sealing. ‘Always use extreme caution when handling gasoline. NOTE: ‘After servicing the valve seats, be sure to check the tappet ‘clearance after the cylinder has been reinstalled. (See pp. 2- 5 ft.) VALVE SPRINGS Check the valve springs for proper strength by measuring their free length and also the force required to compress them, If the spring length is less than the service limit or if the force required to compress the spring does not fall within the specified range, replace the spring. (09900-20201: Vernier calipers Service Limit Valve spring free length: 37.0 mm Standard Valve spring tension: 12.0-14.0 kg/33.7 mmrr ENGINE 3-25 REASSEMBLY Reassemble the cylinder head in the reverse order of disas- sembly. Pay attention to the following points: ¢ Install each valve spring seat ©. © Lubricate the valve stem seal with oil, and press-fit the seal into position by hand. ‘A CAUTION | Do not reuse the valve stem seals. Insert the valves with their stems coated with high qual- ity molybdenum disulfide lubricant (SUZUKI MOLY PASTE). Coat the entire stem making sure that there are no gaps. Also, be sure to oil the valve stem seal lip. A@H99000-25140: SUZUKI MOLY PASTE A CAUTION When inserting each valve, take care not to damage the lip of the stem seal. * Install the valve springs with the smaller pitch @ facing the cylinder head.etn erenreeti eee eetreeee rertetr tiie tinniet etait rene stent 3:27_ ENGINE Install the valve spring retainer ©, press down the spring using the valve lifter and then install the cotter halves onto the valve stem end. Then, release the valve lifter to allow the cotter @ to wedge between the retainer and the valve stem, Be sure that the rounded lip @ of the cotter fits snugly into the groove @ in the stem end. (H] 09916-14510: Valve litter 09916-14530: Valve lifter attachment 09916-84511: Tweezers [A CAUTION Be sure to install all of the parts in their original posi- tions. NOTE: Apply engine oil to the tappet shim and tappet before installing them. CAMSHAFT CAMSHAFT INSPECTION If the engine produces abnormal noises, vibration or lacks power, a camshaft may be distorted or worn to the service limit. The camshaft runout should be checked. Also, check the cams and journals for wear or damage. The exhaust camshaft has the embossed letters “EX” and the intake camshaft has the embossed letters “IN” CAM WEAR Worn-down cams are often the cause of mistimed valve operation resulting in reduced power output. Measure the cam height @) using the micrometer. Replace a camshatt if the cams are worn to the service limit. 09900-20202: Micrometer (25-50 mm) Cam height @) IN: 34.680 mm EX: 33.880 mm- ENGINE 3.28 CAMSHAFT JOURNAL WEAR Determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place. Measure the clearance using the plasti- gauge ©. (6B 09900-22302: Plastigauge NOTE: Install each camshaft journal holder to its original position. Tighten the camshaft journal holder bolts evenly and diag- nally to the specified torque. {8 camshaft journal holder bolt: 10 Nem (1.0 kg-m) NOTE: Do not rotate the camshafts with the plastigauge in place. Remove the camshaft journal holders and measure the width of the compressed plastigauge using the envelope scale. This measurement should be taken at the widest part of the compressed plastigauge. Service Limit Camshatt-Journal oil clearance (IN & EX): 0.150 mm lthe camshaft journal oil clearance exceeds the limit, mea- Sure the inside diameter of the camshaft journal holder and the outside diameter of the camshaft journal. Replace the camshaft or the cylinder head depending upon which one exceeds the specification. (6) 09900-22403: Small bore gauge Standard Camshaft journal holder ILD. (IN & EX): 22.012-22.025 mm (© 09900-20205: Micrometer (0-25 mm) Standard Camshaft journal 0.D. (IN & EX): 21.959-21.980 mm3-29 ENGINE CAMSHAFT RUNOUT Measure the runout using a dial gauge. Replace the cam- he runout exceeds the limit. 09900-20606: Dial gauge (1/100 mm) (09900-20701: Magnetic stand (09900-21304: V-block set (100 mm) Service Limit Camshaft runout (IN & EX): 0.10 mm CAM SPROCKET ‘© When installing each camshaft sprocket to each cam- shaft, align mark “I” with notch © and pin @ on the intake camshaft, or mark “E” with notch @ and pin @ on the exhaust camshaft. ‘© Apply THREAD LOCK SUPER “1303” to the threads of the camshaft sprocket bolts and tighten them to the specified torque. SGI 99000-32030: THREAD LOCK SUPER “1303” (©) camshaft sprocket bolt: 11 Nem (1.1 kg-m) ‘© Be sure to bend the tabs on the camshaft sprocket lock washer so the bolts lock. CAM CHAIN TENSION ADJUSTER The cam chain tension adjuster is maintained at the proper tension by an automatically adjusted tensioner. Insert a flat-head screwdriver into the slotted end of the cam chain tension adjuster and turn it clockwise to release the tension. Remove the screwdriver to make sure that the push rod moves properly. If the push rod is stuck or the spring mechanism does not work, replace the cam chain tension adjuster assembly with a new one. CYLINDER DISTORTION Check the gasket surface of the cylinder for distortion using a straightedge and thickness gauge. Take clearance read- ings at several places. If any reading exceeds the service limit, replace the cylinder. hickness gauge Service Limit: 0.05 mmENGINE 3-30 ' CYLINDER BORE Measure the cylinder bore diameter at six places. If any one of the measurements exceed the limit, overhaul the cylinder and replace the piston with an oversize piston, or replace the cylinder. (GB 09900-20508: Cylinder gauge set Service Limit: 62.080 mm PISTON AND PISTON PIN DIAMETER Measure the piston diameter using the micrometer at 15 mm from the skirt end. If the piston diameter is less than the service limit, replace the piston. (09900-20203: Micrometer (50-75 mm) Service Limit: 61.880 mm Piston over @: 0.5, 1.0 mm | | PISTON-CYLINDER CLEARANCE \ Subtract the piston diameter from the cylinder bore diame- ter. If the piston-to-cylinder clearance exceeds the service limit, rebore the cylinder and use an oversize piston or replace both the cylinder and the piston. Service Limit: 0.120 mm PISTON RING-GROOVE CLEARANCE Measure the side clearances of the 1st and 2nd piston rings __ Using the thickness gauge. If any of the clearances exceed the limit, replace both the piston and piston rings. 09900-20803: Thickness gauge 09900-20205: Micrometer (0-25 mm) Service Limit Piston ring-groove clearance 1st: 0.18 mm 2nd: 0.15 mm i Standard ] Piston ring groove width 1.01-1.03 mm { 1.01-1.03 mm Oil: 2.01-2.03 mm Piston ring thickness 1st and 2nd: NoTe: Remove any carbon from the piston crown and ring Grooves using a soft-metal scraper. .97-0.99 mmie 3-31_ ENGINE PISTON RING END GAP al | Fit the piston ring squarely into the cylinder and measure the piston ring end gap using a thickness gauge. If the piston ring’s end gap is out of specification, replace the piston ring. Service Limit Piston ring end gap 1st and 2nd: 0.50 mm OVERSIZE RINGS Oversize piston ring The following oversize piston ring is used. It bears the fol- lowing identification number. ston ring 1st and 2nd 0.5 mm: 50 1.0 mm: 100 05mmOS. Oversize oil ring The following oversize oil ring is used. It bears the follow- ing identification mark. Oil ring 0.5 mm: Painted red 1.0 mm: Painted yellow Oversize side rail Measure the outside diameter to identify the size. oitsing spacer PIN BORE Measure the piston pin bore inside diameter using the dial calipers and measure the piston pin outside diameter using the micrometer. If either is out of specification or the differ- ence between these two measurements is more than the limits, replace both the piston and piston pin. @®) 09900-20605: Dial calipers 09900-20205: Micrometer (0-25 mm) Piston pin bore: 16.030 mm on pin O.D.: 15.980 mmCRANKSHAFT AND CONROD @ Balancer drive gear @ Bearing Crank pin @Crankshatt, RH @key @Pin @ Crankshaft, RH @Conroa ENGINE 3-32 CONROD SMALL END 1. Measure the conrod small end inside diameter using the dial calipers. If the conrod small end inside diameter ‘®Xceeds the service limit, replace the conrod. © 02900-20608: Dial calipers Service Limit: 16.040 mm33_ ENGINE CONROD DEFLECTION AND CONROD BIG END SIDE CLEARANCE Wear on the big end of the conrod can be estimated by checking the movement of the small end of the rod. This method can also check the extent of wear on the parts of the conrod's big end. 09900-20701: Magnetic stand 09900-20606: Dial gauge (1/100 mm) 09900-21304: V-block set (100 mm) Service Li mm Push the big end of the conrod to one side and measure the side clearance using a thickness gauge. 09900-20803: Thickness gauge ‘Standard: 0.10-0.45mm Service Limit: 1.00 mm If the service limit is exceeded, replace the crankshaft assembly or bring the deflection and side clearance into specification by replacing the worn parts (e.g., conrod, big end bearing and crank pin) (CRANKSHAFT RUNOUT Support the crankshaft with V-blocks as shown. Position the dial gauge, as shown, and rotate the crankshaft slowly to read the runout. Correct the runout or replace the crank- shaft assembly if the runout is greater than the service limit. (@) 02900-20701: Magnetic stand (09900-20606: Dial gauge (1/100 mm) 09900-21304: V-block set (100 mm) Service Limi .08 mm. REASSEMBLY ‘© When rebuilding the crankshaft, the width between the webs should be within the standard range. Standard width between webs @): 5340.1 mm_ENGINE 3-34 7 BALANCER SHAFT AND CRANKSHAFT DRIVEN GEARS tL Fearn nen @Driven gear set DISASSEMBLY # Remove the crankshaft driven gears. © Remove the circlip and washer using the special tool. (09900-06107: snap ring pliers . Separate crankshaft driven gear No.2 @, crankshaft Griven gear No.1 @ and the springs @. 0.e35 _ ENGINE Inspect the balancer shaft and key for wear or damage. e REASSEMBLY Reassemble the balancer shaft and crankshaft driven gears in the reverse order of disassembly. Pay attention to the following points: o fe install the spring washer @ and circlip @ using the spe- cial tool. (@ 02900-06107: Snap ring pliers STARTER CLUTCH AND STARTER DRIVEN GEAR BEARING 10. Nem @ Staner driven gear (1.0 kg-m) @ Bearing @ Starter clutch @ Generator rotor STARTER CLUTCH Install the starter driven gear onto the starter clutch and turn the starter driven gear by hand (the gear turns in only ‘one direction). The starter driven gear should turn smoothly. If excessive resistance is felt while turning the starter driven gear, inspect the starter clutch. Also, inspect ‘the surface of the starter driven gear which contacts the starter clutch, for wear or damage. If any wear or damage is found, replace the defective part(-s)ENGINE 3-26 STARTER DRIVEN GEAR BEARING Install the starter driven gear bearing and gear onto the crankshaft and turn the starter driven gear by hand. Inspect the starter driven gear bearing for smooth rotation and any abnormal noise. If the bearing does not turn smoothly or there is any abnormal noise, replace it. DISASSEMBLY @ Hold the generator rotor with the rotor holder and remove the starter clutch bolts. (GB) 09930-44512: Rotor holder REASSEMBLY © Apply a small quantity of THREAD LOCK SUPER “1303” to the starter clutch bolts and tighten them to the speci- fied torque while holding the rotor holder. +6 99000-32030: THREAD LOCK SUPER “1303” ©) starter clutch bolt: 10 Nem (1.0 kg-m)3:37_ ENGINE TRANSMISSION DISASSEMBLY © Disassemble the transmission gears as shown in the illustration. NOTE: When removing the 2nd drive gear, use a gear puller and a proper attachment. i @ Countershaft @ Eth drive gear @ arayath drive gear @ 6th (top) drive gear @ 2nd drive gear © Driveshaft @ 2nd driven gear @ &th (top) driven gear @ ard driven gear @ ath driven gear @ 5th driven gear | @ 1st (low) driven gear REASSEMBLY ‘Assemble the ceuntershaft and driveshaft in the reverse order of disassembly. Pay attention to the following points: NOTE: Before installing the gears, lightly coat the driveshaft and countershaft with moly paste or ‘engine oil. ‘H199000-25140: SUZUKI MOLY PASTE y Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded and a new circlip must be installed. ing a new circlip, do not expand the end gap larger than required to slip the cir- clip over the shaft. + After installing a cirlip, make sure that itis completely seated in its groove and securely fit- ted,ar ENGINE 3-38 ¢ When installing a new circlip, pay attention to the direc- tion of the circlip. Fit the circlip to the side where the thrust is, as shown in the illustration. The rounded side should be against the gear surface. ‘@ Press fit the 2nd drive gear onto the countershaft. Before reassembling, coat the internal face of the 2nd drive gear with THREAD LOCK SUPER “1303” and install the gears so that the length @ is as shown. Countershaft length @): 88.0 5°! mm. (1st (low) to 2nd) +f 99000-32030: THREAD LOCK SUPER “1303” NOTE: * Take care not to smear THREAD LOCK SUPER “1303” onto the 6th (top) drive gear. + This procedure may be performed only twice before shaft replacement is required. | Sharp edge 4L1eEee °°» ENGINE GEARSHIFT FORKS = Measure the gearshift fork clearance in the groove of its respective gear using the thickness gauge. The clearance for each of the two gearshift forks plays an important role in the smoothness and positiveness of the shifting action. Each fork has its prongs fitted into the annu- lar groove provided in its gear. During operation there is sliding contact between the fork and gear and, when a shifting action is initiated, the fork pushes the gear axially. If the clearance is too great, the meshed gears may slip apart If the clearance exceeds the specification, replace the fork, its respective gear or both. (09900-20803: Thickness gauge Service Limit Gearshift fork to groove clearance: 0.5 mm Standard Gearshift fork groove width No.1: 5,0-5.1 mm No.3: 5.5-5.6mm Gearshift fork thickness 48-49 mm 5.3-5.4mm PRIMARY DRIVE GEARS DISASSEMBLY © Separate primary drive gear No.1 ©, No.2 @ and the springs ®. i REASSEMBLY @ Align the punch mark @ in primary drive gear No.2 with the groove © in primary drive gear No.1.r ENGINE 3.40 CLUTCH CLUTCH DRIVE PLATES. Measure the thickness of the clutch drive plates using ver- nier calipers. If a clutch drive plate is not within the service limit, replace the clutch plates as a set. (09900-20101: vers Service Limit Thickness: 2.6 mm Claw width: 11.0 mm calipers CLUTCH DRIVEN PLATES Measure each clutch driven plate for distortion using the thickness gauge. If a clutch driven plate is not within the service limit, replace the clutch plates as a set. (09900-20803: Thickness gauge Service 0.10 mm CLUTCH SPRING FREE LENGTH Measure the free length of each clutch spring using vernier calipers. If any spring is not within the service limit, replace all of the springs. 09900-20101: Vernier calipers Service Limit: 29.5 mm CLUTCH RELEASE BEARING Inspect the clutch release bearing for any abnormality, specially cracks. When removing the bearing from the Clutch, decide whether it can be reused or if it should be Teplaced, Smooth engagement and disengagement of the clutch depends on the condition of this bearing.ee — 3-41_ ENGINE ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassem- bly. The following steps require special attention or precau- tionary measures should be taken. NOTE: Apply engine oil to each running and sliding part before reassembling. CRANKSHAFT . ‘When installing the crankshaft into the crankcase, necessary to pull its left end into the left crankcase using the special tools. ‘® Apply engine oil to the crankshaft bearings. (B® 09910-32812: Crankshaft installer 09910-20116: Conrod holder ACAUTION Never install the crankshaft into the crankcase by striking it with a plastic hammer. Always use the spe- A cial tool, otherwise the crankshaft may be misaligned. BALANCER SHAFT @ Align the punch mark @ in the drive gear with the hole @ in the driven gear.KICK STARTER ENGINE 3.02 | | | Q Kick starter shaft Q Kick starter Sein uice of ® ? > © Kick starter drive gear Align the punch mark © in the kick starter shaft with the punch mark @ in the kick starter. Turn the kick starter shaft counterclockwise and then lock the kick starter with the kick starter guide. * Install the kick starter drive gear @ and washer @.GEARSHIFT CAM AND GEARSHIFT FORKS © Install the transmission. © Install the gearshift forks and gearshift cam. ©: Gearshift fork No.1 @: Gearshift fork No.3 © Install the gearshift fork shafts (@, @). © Wipe both crankcase mating surfaces with a cleaning solvent. © Apply SUZUKI BOND NO.1215 uniformly to the mating surface of the right crankcase and assemble the cases within a few minutes. =] 99000-31110: SUZUKI BOND NO.1215 © Install the dowel pins © into the left half of the crank- case. © Apply engine oil to the conrod big end and transmission gears. © Tighten the crankcase bolts to the specified torque. ©) crankcase bolt: 10 Nem (1.0 kg-m)P ENGINE 3-44 NOTE: + After the crankcase bolts have been tightened, make sure that the crankshaft rotates smoothly. » if the crankshaft does not rotate smoothly, try to free it by tapping the driveshaft or countershaft with a plastic hammer. GEAR POSITION SWITCH ¢ Install the spring @ and gear position switch contact © and new O-ring @. ¢ Install the gear position switch. ENGINE SPROCKET SPACER Apply SUZUKI SUPER GREASE “A” to the O-ring @ of the engine sprocket spacer and the oil seal lip @, and ‘then install the engine sprocket spacer onto the drive- shaft. A@H99000-25010: SUZUKI SUPER GREASE “A” A CAUTION Use a new O-ring ©. © Install the oil seal retainer ©. CAM CHAIN, CAM CHAIN TENSIONER GUIDE AND GENERATOR ROTOR © Engage the cam chain @ onto the cam chain drive sprocket. Install the cam chain tensioner guide @ and tighten the bolt. © Remove any grease from the tapered portion of the gen- erator rotor and crankshaft. © Install the generator rotor key @.