Suzuki RM 250 2003 Owner's Service Manual
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Suzuki RM 250 2003 Owner's Service Manual

Suzuki RM 250 2003 Owner's Service Manual

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OWNER'S SERVICE MANUAL

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Summary of Contents for Suzuki RM 250 2003

  • Page 1 OWNER’S SERVICE MANUAL...
  • Page 2 This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator. The manual contains important safety information and instructions which should be read carefully before operating the motorcycle.
  • Page 3 PERIODIC MAINTENANCE competition. We sincerely wish you and your Suzuki motorcycle ENGINE DISMOUNTING AND MOUNTING a successful partnership for many years of happy riding.
  • Page 4 HOW TO USE THIS MANUAL TO LOCATE 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 easily.
  • Page 5 Apply THREAD LOCK SUPER “1303”. Data beside it indicates specified 99000-32030 torque. Apply oil. Use engine oil or transmission Use SUZUKI FORK OIL SS-05 or oil unless otherwise specified. equivalent fork oil. 99000-99001-SS5 Apply SUZUKI SUPER GREASE “A”. Use SUZUKI REAR SUSPENSION OIL 99000-25030 (USA) SS-25 or equivalent rear suspension oil.

  • Page 6: Table Of Contents

    GENERAL INFORMATION GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE ............... 1- 2 WARNING/CAUTIONS FOR SERVICING ........... 1- 2 GENERAL CONSIDERATIONS ..............1- 5 SERIAL NUMBER LOCATION ..............1- 6 LOCATION OF PARTS ................1- 7 FUEL AND OIL RECOMMENDATION ............1- 8 OPERATING INSTRUCTIONS ..............1- 9 STARTING THE ENGINE ..............

  • Page 7: Warning/Caution/Note

    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 attention to the mes- sages highlighted by these signal words. ! WARNING Indicates a potential hazard that could result in death or injury.
  • Page 8 GENERAL INFORMATION ! WARNING ! WARNING Fuel can catch on fire if you do not handle Servicing the machine with engine running it properly. Gasoline vapors can catch fire can be hazardous. You can be caught in easily. the moving parts such as the drive chain, sprockets etc.
  • Page 9 * After servicing the fuel, oil, exhaust or brake systems, check all lines and fittings related to the system for leaks CAUTION * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lent. * 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 and orientation.

  • Page 10: General Considerations

    You need to prepare for the unex- pected by wearing a helmet and other protective gear, and practicing safe riding techniques to minimize the damage to you and your machine. May all of your rides on your new Suzuki be winning rides!

  • Page 11: Serial Number Location

    GENERAL INFORMATION SERIAL NUMBER LOCATION The frame number 1 is stamped on the steering head as shown in the photograph. The engine serial num- ber 2 is stamped on the right side of the crankcase assembly. Write down the serial numbers here for your future reference. Frame No.

  • Page 12: Location Of Parts

    GENERAL INFORMATION LOCATION OF PARTS 1 Clutch lever 2 Engine stop switch 3 Clutch cable adjuster 4 Throttle grip 5 Front brake lever 6 Fuel tank cap 7 Starter knob 8 Gearshift lever 9 Fuel valve 0 Kick starter lever A Rear brake pedal...

  • Page 13: Fuel And Oil Recommendation

    GENERAL INFORMATION FUEL AND OIL RECOMMENDATION This motorcycle is of the two-stroke design, which requires a premixture of gasoline and oil. Gasoline: Use only unleaded gasoline of at least 90 pump octane (R/2 + M/2)..For Canada Use only unleaded gasoline of at least 95 octane (Research Method).

  • Page 14: Operating Instructions

    GENERAL INFORMATION OPERATING INSTRUCTIONS STARTING THE ENGINE Inspect the transmission oil level, coolant level and air cleaner condition before starting the engine. When the engine is cold: 1) Turn the fuel valve lever to the “ON” position. 2) Shift the transmission into neutral. 3) Pull the bypass (starter) knob 1.

  • Page 15: Stopping The Engine

    1-10 GENERAL INFORMATION STOPPING THE ENGINE 1) Shift the transmission into neutral. 2) Turn the fuel valve lever to the “OFF” position. 3) Push the engine stop switch 2 to stop the engine. ! WARNING Leaving the fuel valve in the “ON” position may cause carburetor overflow.

  • Page 16: Country And Area Codes

    GENERAL INFORMATION 1-11 COUNTRY AND AREA CODES The following codes stand for the applicable country(-ies) and area(-s). CODE COUNTRY or AREA Japan E-03 U. S. A. E-28 Canada...
  • Page 17 PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE ................ 2- 3 PERIODIC MAINTENANCE CHART ............ 2- 3 INSPECTION BEFORE PRACTICE ............2- 5 INSPECTION BEFORE RACE .............. 2- 5 SPARK PLUG ....................2- 6 AIR CLEANER ..................... 2- 7 AIR CLEANER ELEMENT REMOVAL ..........2- 7 WASHING ....................
  • Page 18 PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS DRIVE CHAIN GUIDE, BUFFER, CONTROL ROLLER ......2-18 DRIVE CHAIN GUIDE ................2-18 DRIVE CHAIN GUIDE BUFFER ............2-18 DRIVE CHAIN CONTROL ROLLER ............ 2-18 BRAKES ...................... 2-18 BRAKE FLUID LEVEL ................. 2-18 BRAKE PAD ..................2-19 FRONT BRAKE LEVER ADJUSTMENT ..........

  • Page 19: Periodic Maintenance

    PERIODIC MAINTENANCE PERIODIC MAINTENANCE PERIODIC MAINTENANCE CHART It is very important to inspect and maintain the machine regularly. Follow the guideline in the chart. The life of parts varies depending on the riding conditions. Perform more often than shown in the chart if you use the motorcycle under severe conditions.
  • Page 20 PERIODIC MAINTENANCE Interval Every Every Every races race 3 races 5 races Remarks Service Every Every Every hours Item 2 hours 6 hours 10 hours Tire — — Inspect every 20 min. up to initial 2 hours Spoke nipple — —...

  • Page 21: Inspection Before Practice

    PERIODIC MAINTENANCE INSPECTION BEFORE PRACTICE WHAT TO CHECK CHECK FOR Spark plug • Heat range, fouled electrode, tightness • Loose high-tension cord Air cleaner element Lubrication Transmission oil Oil level Coolant Coolant level Cooling system • Radiator hose damage • Engine coolant leak Clutch •...

  • Page 22: Spark Plug

    PERIODIC MAINTENANCE SPARK PLUG Inspect the spark plug condition, electrode color, carbon depos- its, spark plug gap, and washer damage, after removing the spark plug. NOTE: Remove the dirt around the spark plug before removing the spark plug to prevent dirt from entering the combustion cham- ber.

  • Page 23: Air Cleaner

    PERIODIC MAINTENANCE AIR CLEANER AIR CLEANER ELEMENT REMOVAL • Remove the seat. (!3-2) • Remove screw 1. • Remove the element from the element holder. WASHING • Fill a washing pan that is large enough to hold the element with non-flammable cleaning solvent A. Immerse the element in the solvent and wash it.
  • Page 24 PERIODIC MAINTENANCE NOTE: Follow the instructions below to keep the air cleaner element dry when cleaning the motorcycle. * Cover the element with a plastic bag. * Install the seat. * Cover the inlet holes on the frame covers to prevent water from coming into the air cleaner box.

  • Page 25: Transmission Oil

    PERIODIC MAINTENANCE TRANSMISSION OIL TRANSMISSION OIL LEVEL INSPECTION AND REPLENISHMENT % WARNING Transmission oil and exhaust pipe can be hot enough to burn you. Wait until the oil drain plug and exhaust pipe become cool enough to touch with bare hands before draining oil.

  • Page 26: Transmission Oil Change

    2-10 PERIODIC MAINTENANCE TRANSMISSION OIL CHANGE • Warm up the engine. • Place the motorcycle on the level ground and hold the motor- cycle vertically. • Remove filler cap and drain plug 3. Drain oil thoroughly. • Tighten the drain plug firmly. $ Oil drain plug: 21 N·m (2.1 kgf-m, 15.0 lb-ft) •...

  • Page 27: Engine Coolant

    PERIODIC MAINTENANCE 2-11 ENGINE COOLANT ENGINE COOLANT LEVEL CHECK % WARNING You can be injured by scalding fluid or steam if you open the radiator cap when the engine is hot. Do not open the radiator cap when the engine is hot. Wait until engine cools.

  • Page 28: Engine Coolant Replenishment

    2-12 PERIODIC MAINTENANCE ENGINE COOLANT REPLENISHMENT % WARNING Engine coolant is harmful if swallowed or if it comes in contact with your skin or eyes. Keep engine coolant away from children and pets. Call your doctor immediately if engine coolant is swal- lowed and induce vomiting.

  • Page 29: Clutch

    PERIODIC MAINTENANCE 2-13 CLUTCH Adjust the clutch cable play as follows: MAJOR ADJUSTMENT • Loosen the locknut 1. • Turn the adjuster 2 so that the clutch lever obtains 10 – 15 mm (0.4 – 0.6 in) play at the clutch lever end. •...

  • Page 30: Fuel Hose

    2-14 PERIODIC MAINTENANCE • Remove the throttle housing cover. • Apply oil to the throttle cable 3. (!2-23) • Apply oil to the throttle cable spool 4. (!2-23) FUEL HOSE Inspect the fuel hose for damage and fuel leakage. If any defects are found, the fuel hose must be replaced.

  • Page 31: Cylinder Head, Cylinder And Piston

    PERIODIC MAINTENANCE 2-15 CYLINDER HEAD, CYLINDER AND PISTON CYLINDER HEAD • Remove the cylinder head. (!4-3) • Remove carbon deposits from combustion chamber surface. • Inspect for pinholes, cracks and other damage. CYLINDER • Remove the cylinder. (!4-3) • Remove carbon deposits from the exhaust port and the exhaust valve chamber A.

  • Page 32: Exhaust Silencer

    • Replace the glasswool silencer with new one if necessary. NOTE: To seal between the frontal part and the aluminum case, apply SUZUKI BOND “1207B” to the contact area of the frontal part. ' 99000-31140: SUZUKI BOND “1207B” DRIVE CHAIN AND SPROCKETS DRIVE CHAIN SLACK •...

  • Page 33: 20Th Pitch Length

    • Clean the drive chain with non-flammable cleaning solvent. • Do not use gasoline to clean the drive chain. • Dry the drive chain. • Apply Suzuki Chain Lube or an equivalent to the link plates and rollers. • Reassemble the drive chain.

  • Page 34: Drive Chain Guide, Buffer, Control Roller

    2-18 PERIODIC MAINTENANCE DRIVE CHAIN GUIDE, BUFFER, CONTROL ROLLER DRIVE CHAIN GUIDE Inspect the drive chain guide 1 for bends and damage. NOTE: The drive chain can hit a bent guide causing noise and drive chain wear. Inspect the chain guide defense 2 for wear. DRIVE CHAIN GUIDE BUFFER Inspect the drive chain guide buffer 3 for wear and cracks.

  • Page 35: Steering

    A. Lightweight oil such as WD-40 or penetrating oil. B. Aerosol type Chain Lube. C. SUZUKI SUPER GREASE “A” or water-proof wheel bearing grease. Follow the schedule closely. The disassembly necessary to lubricate many components is in itself valuable preventative maintenance. It allows you to inspect for wear, fatigue, adjustment and fastener tightness and it...
  • Page 36 ENGINE DISMOUNTING AND MOUNTING ENGINE DISMOUNTING AND MOUNTING CONTENTS ENGINE DISMOUNTING ................3- 2 ENGINE MOUNTING ................... 3- 5 INSPECTION AFTER ENGINE MOUNTING ..........3- 6...
  • Page 37 ENGINE DISMOUNTING AND MOUNTING ENGINE DISMOUNTING • Drain transmission oil. (!2-9) • Drain engine coolant. (!2-12) • Remove the seat. • Remove the fuel tank with the radiator cover. • Remove the carburetor. (!9-10) • Remove the exhaust pipe fitting springs with the special tool. "...
  • Page 38 ENGINE DISMOUNTING AND MOUNTING • Remove the exhaust pipe gasket. • Disconnect the radiator hoses 1. • Disconnect the spark plug cap 2. • Disconnect the magneto lead wire coupler 3 and clamp 4. • Remove the clip and open the chain. •...
  • Page 39 ENGINE DISMOUNTING AND MOUNTING • Remove the magneto cover. (!7-3) • Disconnect the clutch cable. NOTE: Loosen the clutch cable adjuster when disconnecting. (!2-13) • Remove the engine mounting bolts and brackets. • Remove the swingarm pivot shaft nut 5 and washer. •...
  • Page 40 ENGINE DISMOUNTING AND MOUNTING ENGINE MOUNTING • Mount the engine from the right side. • Tighten the engine mounting bolts/nuts to the specified torque. N·m kgf-m lb-ft 31.0 3 4 5 32.5 50.5 Bolt Diameter Bolt Length 8 mm (0.3 in) 45 mm (1.8 in) 8 mm (0.3 in) 55 mm (2.2 in)
  • Page 41 ENGINE DISMOUNTING AND MOUNTING Install the parts in the reverse order of removal. Pay attention to the following points: • Tighten the brake pedal pivot bolt 1. # Brake pedal pivot bolt: 29 N·m (2.9 kgf-m, 21.0 lb-ft) CAUTION Replace the cotter pins with new ones. •...
  • Page 42 CYLINDER, CYLINDER HEAD AND PISTON CYLINDER, CYLINDER HEAD AND PISTON CONTENTS CONSTRUCTION ..................4- 2 REMOVAL ....................4- 3 CYLINDER HEAD ................. 4- 3 CYLINDER ..................... 4- 3 PISTON AND PISTON RING ..............4- 4 INSPECTION ....................4- 5 CYLINDER HEAD ................. 4- 5 CYLINDER .....................

  • Page 43: Construction

    CYLINDER, CYLINDER HEAD AND PISTON CONSTRUCTION 20 N . m (2.0 kgf-m, 14.5 lb-ft) 45 N . m (4.5 kgf-m, 33.0 lb-ft) 25 N . m (2.5 kgf-m, 18.0 lb-ft) 4.5 N . m (0.45 kgf-m, 3.3 lb-ft) 38 N . m (3.8 kgf-m, 27.5 lb-ft) 4.5 N .

  • Page 44: Removal

    CYLINDER, CYLINDER HEAD AND PISTON REMOVAL CYLINDER HEAD • Drain engine coolant. (!2-12) • Remove the seat and fuel tank. (!3-2) • Disconnect the radiator hose 1. • Disconnect the spark plug cap 2 and remove the spark plug • Remove the engine mounting brackets 4. •...

  • Page 45: Piston And Piston Ring

    CYLINDER, CYLINDER HEAD AND PISTON • Remove the exhaust valve rod bolt 4. • Remove the cylinder nuts. NOTE: Loosen the cylinder nuts diagonally. • Remove the radiator lower mounting bolts (left & right) and move the radiator forward. • Remove the cylinder. NOTE: Take care not to drop the exhaust side valve spacer 5.

  • Page 46: Inspection

    CYLINDER, CYLINDER HEAD AND PISTON INSPECTION CYLINDER HEAD • Remove carbon deposits from the cylinder head. • Inspect the cylinder head for cracks around the spark plug hole. • Inspect for cylinder head distortion with the thickness gauge. " Cylinder head distortion Service limit: 0.05 mm (0.002 in) # 09900-20803: Thickness gauge CYLINDER...

  • Page 47: Conrod

    CYLINDER, CYLINDER HEAD AND PISTON CONROD • Measure the conrod small end bore. (!8-8) PISTON AND PISTON RING • Remove carbon deposits from the piston. • Inspect the piston for wear, scratches and damage. • Measure the piston outer diameter at 25.5 mm (1.00 in) from the skirt end.

  • Page 48: Installation

    CYLINDER, CYLINDER HEAD AND PISTON • Measure the piston ring free end gap. " Piston ring free end gap Service limit: 6.7 mm (0.26 in) # 09900-20101: Vernier calipers INSTALLATION PISTON AND PISTON RING Install the piston and piston ring in the reverse order of removal. Pay attention to the following points: •...

  • Page 49: Cylinder

    CYLINDER, CYLINDER HEAD AND PISTON • Face the embossed mark on the piston top to the exhaust port side. • Install the piston pin and new piston pin circlips. NOTE: * Place cloth under the piston to prevent the piston pin circlip from dropping into the crankcase chamber.

  • Page 50: Cylinder Head

    NOTE: Apply Bond “1207B” to the stud bolt threads when assembling the removed stud bolts into the cylinder. % 99000-31140: SUZUKI BOND “1207B” CYLINDER HEAD • Tighten the cylinder head nuts to the specified torque accord- ing to the specified tightening order as shown.
  • Page 51 CLUTCH CLUTCH CONTENTS CONSTRUCTION ..................5- 2 REMOVAL ....................5- 3 CLUTCH PLATE ................... 5- 3 PRIMARY DRIVEN GEAR ..............5- 4 CLUTCH RELEASE CAMSHAFT ............5- 4 INSPECTION ....................5- 5 DRIVE PLATE ..................5- 5 DRIVEN PLATE ..................5- 5 CLUTCH SPRING .................

  • Page 52: Construction

    CLUTCH CONSTRUCTION 10 N·m (1.0 kgf-m, 0.7 lb-ft) 5 N·m (0.5 kgf-m, 3.5 lb-ft) 90 N·m (9.0 kgf-m, 65.0 lb-f No. 1 drive plate No. 2 drive plate...

  • Page 53: Removal

    CLUTCH REMOVAL CLUTCH PLATE • Drain transmission oil. (!2-9) • Remove the rear brake pedal. (!3-3) • Remove the clutch cover 1. • Loosen and remove the bolts diagonally. • Remove the clutch springs. • Remove the pressure plate 2. •...

  • Page 54: Primary Driven Gear

    CLUTCH PRIMARY DRIVEN GEAR • Remove the clutch cover. ( !5-3) • Remove the clutch plates. (!5-3) • Flatten the lock washer 1. • Hold the clutch sleeve hub 2 with the special tool and remove the nut 3. " 09920-53740: Clutch sleeve hub holder •...

  • Page 55: Inspection

    CLUTCH INSPECTION DRIVE PLATE • Inspect the drive plates for wear, distortion and discoloration. • Measure the drive plate thickness. # Drive plate thickness Service limit: 2.77 mm (0.109 in) " 09900-20101: Vernier calipers • Measure the drive plate claw width. # Drive plate claw width Service limit: 13.05 mm (0.514 in) "...

  • Page 56: Clutch Push Rod

    CLUTCH CLUTCH PUSH ROD • Inspect the clutch push piece, bearing and push rod for wear and damage. PRIMARY DRIVEN GEAR AND CLUTCH SLEEVE HUB • Inspect the clutch sleeve hub and primary driven gear assem- bly for wear and cracks. BEARING AND SPACER •...

  • Page 57: Installation

    CLUTCH INSTALLATION Install the clutch assembly in the reverse order of removal. Pay attention to the following points. PRIMARY DRIVEN GEAR • Apply transmission oil to the spacer 1 and needle bearing 2. • Fit the clutch sleeve hub 3, new lock washer 4 and clutch sleeve hub nut 5.

  • Page 58: Clutch Plate

    CLUTCH CLUTCH PLATE • Apply transmission oil to the drive plates and driven plates. • Install the clutch drive plates and driven plates one by one into the clutch sleeve hub in the prescribed order as show in illustration. Direction of outside Friction segment Drive Number of...

  • Page 59: Magneto Cover

    CLUTCH • Fit the clutch cover 1. • Tighten the bolts to the specified torque. $ Clutch cover bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft) MAGNETO COVER • Install the clutch release camshaft. • Install the magneto rotor and stator. (!7-4) •...
  • Page 60 KICK STARTER KICK STARTER CONTENTS CONSTRUCTION ..................6- 2 REMOVAL ....................6- 3 INSPECTION ....................6- 3 REASSEMBLY .................... 6- 4 INSPECTION AFTER REASSEMBLY ............6- 5...

  • Page 61: Construction

    KICK STARTER CONSTRUCTION 23 N·m (2.3 kgf-m, 16.5 lb-ft) 10 N·m (1.0 kgf-m, 7.0 lb-ft)

  • Page 62: Removal

    KICK STARTER REMOVAL • Drain transmission oil. (!2-9) • Drain the engine coolant. (!2-12) • Remove the rear brake pedal. (!3-3) • Remove the kick starter lever. • Remove the crankcase cover. • Remove the clutch. (!5-3, 4) • Remove the kick starter idle gear 1 and washer. "...

  • Page 63: Reassembly

    KICK STARTER • Inspect the return spring for damage. • Inspect the kick starter drive gear teeth for wear and damage. • Inspect the kick starter drive gear ratchet part for wear and damage. • Inspect the kick starter shaft and drive gear contact surface for wear and damage.

  • Page 64: Inspection After Reassembly

    KICK STARTER • Install the clutch. (!5-7) • Fit a new gasket and install the crankcase cover. # Crankcase cover bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft) • Install the kick starter lever with the punched mark on the lever aligned with the punched mark on the kick starter shaft. # Kick starter lever bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) •...
  • Page 65 MAGNETO ROTOR AND STATOR MAGNETO ROTOR AND STATOR CONTENTS CONSTRUCTION ..................7- 2 REMOVAL ....................7- 3 INSTALLATION ................... 7- 4 INSPECTION AFTER INSTALLATION ............7- 5...

  • Page 66: Construction

    MAGNETO ROTOR AND STATOR CONSTRUCTION 10 N·m (1.0 kgf-m, 7.0 lb-ft) 55 N·m (5.5 kgf-m, 40.0 lb-ft) 11 N·m (1.1 kgf-m, 8.0 lb-ft)

  • Page 67: Removal

    MAGNETO ROTOR AND STATOR REMOVAL • Remove the seat. (!3-2) • Remove the fuel tank. (!3-2) • Disconnect the magneto lead wire coupler 1 and clamp 2. • Remove the magneto cover. • Remove the magneto rotor nut with the special tool. "...

  • Page 68: Installation

    MAGNETO ROTOR AND STATOR • Remove the stator. • Remove the key 3. INSTALLATION Install the stator and magneto rotor in the reverse order of removal. Pay attention to the following points: • Degrease the tapered portion of the crankshaft and magneto rotor.

  • Page 69: Inspection After Installation

    MAGNETO ROTOR AND STATOR • Fit a new gasket. • Tighten the magneto cover bolts to the specified torque. # Magneto cover bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft) INSPECTION AFTER INSTALLATION After installing the stator and magneto rotor, inspect the follow- ing.
  • Page 70 TRANSMISSION AND CRANKSHAFT TRANSMISSION AND CRANKSHAFT CONTENTS CONSTRUCTION ..................8- 2 CRANKSHAFT AND CRANKCASE ............. 8- 2 TRANSMISSION ................... 8- 3 REMOVAL ....................8- 4 GEARSHIFT LINKAGE ................. 8- 4 PRIMARY DRIVE GEAR ............... 8- 4 CRANKCASE ..................8- 5 TRANSMISSION ...................

  • Page 71: Construction

    8-2 TRANSMISSION AND CRANKSHAFT CONSTRUCTION CRANKSHAFT AND CRANKCASE 70 N·m (7.0 kgf-m, 50.5 lb-ft) 21 N·m (2.1 kgf-m, 15.0 lb-ft) 5.5 N·m (0.55 kgf-m, 4.0 lb-ft)

  • Page 72: Transmission

    TRANSMISSION AND CRANKSHAFT TRANSMISSION 23.5 N·m (2.35 kgf-m, 17.0 lb-ft) 10 N·m (1.0 kgf-m, 7.0 lb-ft) 10 N·m (1.0 kgf-m, 7.0 lb-ft) 10 N·m (1.0 kgf-m, 7.0 lb-ft) 10 N·m (1.0 kgf-m, 7.0 lb-ft)

  • Page 73: Removal

    8-4 TRANSMISSION AND CRANKSHAFT REMOVAL • Dismount the engine. (!3-2) • Remove the cylinder and piston. (!4-3, 4) • Remove the crankcase cover and clutch. (!5-3) • Remove the kick starter system. (!6-3) • Remove the exhaust valve governor assembly. (!11-8) •...

  • Page 74: Crankcase

    TRANSMISSION AND CRANKSHAFT CRANKCASE • Remove the crankcase bolts. • Separate the crankcase with the special tool. " 09920-13120: Crankcase separating tool NOTE: * Set the crankcase separating tool to the clutch side of the crankcase. * Keep all the tool arms parallel to the crankcase surface. * Separate the crankcase gradually while tapping the crankcase boss and countershaft softly with a plastic hammer.

  • Page 75: Crankshaft

    8-6 TRANSMISSION AND CRANKSHAFT CRANKSHAFT • Remove the crankshaft with the special tool. " 09920-13120: Crankcase separating tool NOTE: * Keep all the tool arms parallel to the crankcase surface. INSPECTION GEARSHIFT SHAFT • Inspect the gearshift shaft for bends and damage. •...
  • Page 76 TRANSMISSION AND CRANKSHAFT • Inspect the gearshift cam groove for abnormal wear and dam- age. • Inspect the gearshift forks and shafts for wear and damage. • Measure the gearshift fork thickness with the vernier calipers. # Gearshift fork thickness Standard: 4.60 –...

  • Page 77: Crankshaft

    8-8 TRANSMISSION AND CRANKSHAFT CRANKSHAFT • Measure the crankshaft runout with the V-blocks and dial gauge. # Crankshaft runout Service limit: 0.05 mm (0.002 in) " 09900-20602: Dial gauge 09900-20701: Magnetic stand 09900-21304: V-block • Measure the crankshaft web to web width with the vernier cal- ipers.

  • Page 78: Crank Case

    TRANSMISSION AND CRANKSHAFT CRANK CASE OIL SEAL INSPECTION AND REMOVAL • Inspect the oil seal lips for wear and damage. • Remove the oil seal with the special tool. " 09913-50121: Oil seal remover OIL SEAL INSTALLATION • Fit a new oil seal with the special tool. •...

  • Page 79: Bearing Inspection, Removal And Installation

    8-10 TRANSMISSION AND CRANKSHAFT BEARING INSPECTION, REMOVAL AND INSTALLATION • Inspect the bearings for play, discoloration, wear and seizure. • Move the inner race by finger and inspect for smooth move- ment. • Remove the bearing retainers. • Remove and install the bearings with the special tool. "...

  • Page 80: Installation

    TRANSMISSION AND CRANKSHAFT 8-11 INSTALLATION Install the crankshaft and transmission in the reverse order of removal. Pay attention to the following points: CRANKSHAFT • Install the crankshaft into the left crankcase half with the spe- cial tool. " 09910-32812: Crankshaft installer 09911-11310: Attachment NOTE: Do not hit the crankshaft with a hammer for installation.

  • Page 81: Crankcase

    • Inspect the crankshaft, countershaft and drive shaft for smooth movement. • Apply grease to new O-rings. Fit the two O-rings and spacer to the driveshaft. • Remount the engine sprocket. % SUZUKI SUPER GREASE “A”...

  • Page 82: Gearshift Linkage

    TRANSMISSION AND CRANKSHAFT 8-13 • Reassemble the primary drive gear and washer. NOTE: The washer is directional. Assemble the washer as shown in the illustration. • Install the magneto rotor and stator. (!7-4) • While holding the magneto rotor with the special tool, tighten the primary drive gear bolt 1 to the specified torque.

  • Page 83: Inspection After Installation

    8-14 TRANSMISSION AND CRANKSHAFT • Install the gearshift cam driven gear. • Apply THREAD LOCK SUPER and tighten the retainer screws 3 to the specified torque. & 99000-32030: THREAD LOCK SUPER “1303” $ Retainer screw: 10 N·m (1.0 kgf-m, 7.0 lb-ft) •...
  • Page 84 FUEL SYSTEM 9-1 FUEL SYSTEM CONTENTS CONSTRUCTION ..................9- 2 CARBURETOR TUNING ................9- 3 PRINCIPLES OF CARBURETOR TUNING .......... 9- 3 CARBURETOR TUNING IN PRACTICE ..........9- 7 CARBURETOR .................... 9-10 REMOVAL AND DISASSEMBLY ............9-10 INSPECTION ..................9-12 REASSEMBLY AND REMOUNTING ............

  • Page 85: Construction

    FUEL SYSTEM CONSTRUCTION 4.5 N·m (0.45 kgf-m, 3.25 lb-ft)

  • Page 86: Carburetor Tuning

    Riders who are not familiar with the operation and jetting procedures of the KEIHIN carburetor should have their local authorized Suzuki dealer perform these alterations. Mechanically experienced riders can alter the carburetor settings based on the fol- lowing information and specifications.
  • Page 87 FUEL SYSTEM As shown below, each of the asterisk (*) marked parts is located between the air/fuel passage and has its own air/fuel mixture adjustable range in terms of the throttle valve opening. The chart indicates that the car- buretor can supply correct air/fuel mixture to the engine in any range because of the overlapping adjustable range of the each part.
  • Page 88 FUEL SYSTEM Needle Clip Position Jet Needle Lean Needle O.D. of Needle clip Rich Clip The jet needle is linked to the throttle valve by Needle number means of the needle clip. Its lower part is tapered NEDH and it has five grooves cut in the upper part where O.D.
  • Page 89 FUEL SYSTEM Throttle stop screw When the throttle stop screw is turned clockwise, the throttle valve is forced upward allowing the engine to continue idling. Throttle valve opening After touching the throttle stop screw to the Standard throttle valve, turn in the stop screw five to six turns to raise the throttle valve.

  • Page 90: Carburetor Tuning In Practice

    FUEL SYSTEM CARBURETOR TUNING IN PRACTICE In the previous section, basic principles of carburetor tuning have been discussed. Described in this section are the bases for carburetor tuning required when coping with variations in air (oxygen) concentration. Variation in Air (Oxygen) Concentration and Carburetor Conditions As the air, affected by the temperature, altitude and humidity, gets expanded or compressed, air (oxygen) concentration varies accordingly.
  • Page 91 FUEL SYSTEM Judging Air/Fuel Mixture Included Parts and Optional Parts For proper carburetor tuning, it is necessary to know how to judge the air/fuel mixture made in the Main jet carburetor; whether too rich, too lean or properly Air/fuel mixed. Given below are the symptoms observed SIZE P/NO.
  • Page 92 FUEL SYSTEM 2 Adjustment of main system Jet needle With the throttle opened 3/4 to full, make main sys- Air/fuel SIZE P/NO. tem adjustment monitoring the air/fuel mixture con- mixture dition after completion of slow system settings. Lean NECL 13383-37FG0 * Make sure to adjust the main system before NEDL 13383-37FP0...

  • Page 93: Carburetor

    9-10 FUEL SYSTEM CARBURETOR REMOVAL AND DISASSEMBLY • Remove the seat and fuel tank. (!3-2) • Disconnect the throttle position sensor and solenoid couplers. • Loosen the carburetor clamp screws and remove the carbure- tor 1. CAUTION Do not bend the throttle cable and do not damage the throttle position sensor.
  • Page 94 FUEL SYSTEM 9-11 • Carburetor top cap 5 • Throttle valve spring 6 • Throttle valve collar 7 • Cable holder 8 • Jet needle 9 • Throttle valve 0 • Remove the screws and carburetor float chamber A. • Remove the float pin B and floats C. •...

  • Page 95: Inspection

    9-12 FUEL SYSTEM INSPECTION • Inspect the following parts for damage: Jet needle Throttle valve Float • Inspect the following jets for clogging: Main jet Slow jet Good Worm Starter jet Power jet • Inspect the needle valve for wear. •...

  • Page 96: Carburetor Solenoid

    FUEL SYSTEM 9-13 CARBURETOR SOLENOID REMOVAL AND INSPECTION • Remove the solenoid. • Connect the coupler 1. • Connect tachometer sensor plug 2 to the Multi circuit tester. # 09900-25008: Multi circuit tester set Tester knob indication: RPM A • Pinch the high tension cord with the tachometer sensor 3. •...

  • Page 97: Throttle Position Sensor

    9-14 FUEL SYSTEM THROTTLE POSITION SENSOR INSPECTION • Disconnect the throttle position sensor coupler. • Start the engine. Orange/ • Measure the throttle position sensor input voltage with the Black/Yellow White Multi circuit tester. # 09900-25008: Multi circuit tester set $ Tester knob indication: Voltage (%) "...

  • Page 98: Removal And Remounting

    FUEL SYSTEM 9-15 REMOVAL AND REMOUNTING • Remove the carburetor. (!9-10) • Remove the bolts 1 and remove the throttle position sensor 2 with the special tool. # 09930-11960: Torx wrench, T20 • Remount the throttle position sensor assembly. CAUTION Do not loosen the bolt A.
  • Page 99 COOLING SYSTEM 10-1 COOLING SYSTEM CONTENTS CONSTRUCTION ..................10- 2 COOLING CIRCUIT INSPECTION ............10- 3 COOLING CIRCUIT ................10- 3 RADIATOR CAP ................. 10- 3 REMOVAL ....................10- 3 RADIATOR ..................10- 3 WATER PUMP ..................10- 4 INSPECTION ..................... 10- 4 RADIATOR ..................

  • Page 100: Construction

    10-2 COOLING SYSTEM CONSTRUCTION 5.5 N . m (0.55 kgf-m, 4.0 lb-ft) 10 N . m (1.0 kgf-m, 7.0 lb-ft)

  • Page 101: Cooling Circuit Inspection

    COOLING SYSTEM 10-3 COOLING CIRCUIT INSPECTION COOLING CIRCUIT Before removing the radiator and draining engine coolant, inspect the cooling circuit for tightness. • Remove the radiator cap. • Connect the tester 1 to the filler. # WARNING Do not remove the radiator cap when the engine is hot.

  • Page 102: Water Pump

    10-4 COOLING SYSTEM WATER PUMP • Drain the engine coolant. (" 2-12) • Drain the transmission oil. (" 2-9) • Remove the kick starter lever. (" 6-3) • Remove the brake pedal. (" 3-3) • Disconnect the radiator hose 1. •...

  • Page 103: Impeller And Gear Shaft

    COOLING SYSTEM 10-5 IMPELLER AND GEAR SHAFT • Inspect the impeller and gear shaft for damage. WATER PUMP BEARING Play Inspect the inner race play of the water pump bearing while it is Play in the water pump housing. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation.

  • Page 104: Reassembly

    10-6 COOLING SYSTEM REASSEMBLY Reassemble and remount the water pump in the reverse order of removal and disassembly. Pay attention to the following points: • Tighten the impeller to the specified torque. & Impeller: 10 N·m (1.0 kgf-m, 7.0 lb-ft) CAUTION The impeller has left-hand threads.

  • Page 105: Inspection After Reassembly

    COOLING SYSTEM 10-7 • Install the dowel pins 1 and new gasket 2. CAUTION Use a new gasket to prevent engine coolant leakage. • Tighten the crankcase cover bolts to the specified torque. & Crankcase cover bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft) INSPECTION AFTER REASSEMBLY After reinstalling the water pump, inspect the followings.
  • Page 106 EXHAUST VALVE 11-1 EXHAUST VALVE CONTENTS CONSTRUCTION ..................11- 2 EXHAUST VALVE ..................11- 3 DISASSEMBLY ................... 11- 3 INSPECTION ..................11- 5 REASSEMBLY ..................11- 5 EXHAUST VALVE GOVERNER AND ACTUATOR ........11- 8 DISASSEMBLY ................... 11- 8 INSPECTION ..................11- 9 REASSEMBLY ..................

  • Page 107: Construction

    11-2 EXHAUST VALVE CONSTRUCTION 4.5 N . m (0.45 kgf-m, 3.3 lb-ft) 4.0 N . m (0.4 kgf-m, 3.0 lb-ft) 10 N . m (1.0 kgf-m, 7.0 lb-ft) 4.5 N . m (0.45 kgf-m, 3.3 lb-ft)

  • Page 108: Exhaust Valve

    EXHAUST VALVE 11-3 EXHAUST VALVE DISASSEMBLY • Remove the cylinder. (!4-3) EXHAUST SIDE VALVE (RH) • Remove the exhaust side valve spacer 1. • Remove the exhaust side valve cam 2 and shaft 3. • Remove the exhaust side valve bolt 4, stopper pin 5 and gasket 6.
  • Page 109 11-4 EXHAUST VALVE EXHAUST SIDE VALVE (LH) • Remove the side valve cap 1. • Remove the exhaust side valve in the same manner as the right side. • Remove the spring cap 2. • Remove the gasket 3 and spring 4. EXHAUST MAIN VALVE •...

  • Page 110: Inspection

    EXHAUST VALVE 11-5 • Remove the exhaust valve shaft 3. • Remove the following parts. 4 Spacer 5 Exhaust valve arm 6 Spring 7 Right exhaust side valve rod 8 Left exhaust side valve rod • Remove the retainer 9 and the exhaust main valve 0. INSPECTION •...
  • Page 111 11-6 EXHAUST VALVE • Apply transmission oil to the exhaust valve shaft. • Install the springs 3 to the valve arm 4. • Insert the exhaust valve shaft through the spacers 5 and valve arm with springs. • Apply transmission oil to the exhaust main valve. •...
  • Page 112 EXHAUST VALVE 11-7 • Temporarily tighten the bolts C. • Turn the cap 180° clockwise and tighten the bolts to the spec- ified torque. " Exhaust valve return spring cap bolt: 4.5 N·m (0.45 kgf-m, 3.3 lb-ft) • Install the exhaust side valve D, stopper pin E and new gas- ket F.

  • Page 113: Exhaust Valve Governer And Actuator

    11-8 EXHAUST VALVE • Install a new gasket and the cap. • Tighten the bolts to the specified torque. " Exhaust side valve cover bolt: 4.5 N·m (0.45 kgf-m, 3.3 lb-ft) • After assembling the exhaust valve, inspect it for smoothness by rotating the exhaust valve shaft.

  • Page 114: Inspection

    EXHAUST VALVE 11-9 • Remove the exhaust valve rod assembly 3. • Disassemble the governer assembly by pushing down the retainer 4. INSPECTION • Inspect the disassembled parts for wear and damage. • Inspect the exhaust valve rod for smooth movement. REASSEMBLY Reassemble the exhaust valve governer and actuator in the reverse order of disassembly.

  • Page 115: Inspection After Installation

    11-10 EXHAUST VALVE • Install the exhaust valve governer with the exhaust valve rod A engaged with the groove B of the governer. • Connect the exhaust valve rod to the exhaust valve shaft using the pin 1 as a stopper. NOTE: The pin 1 is one of the included parts.
  • Page 116 CONSTRUCTIONS 12-1 CONSTRUCTIONS CONTENTS EXTERIOR PARTS ..................12- 2 HANDLEBAR CONTROLS ............... 12- 3 REMOVAL ................... 12- 3 REMOUNTING ..................12- 4 SEAT RAIL, DRIVE CHAIN CONTROL ROLLER ........12- 6...

  • Page 117: Exterior Parts

    12-2 CONSTRUCTIONS EXTERIOR PARTS 5 N·m (0.5 kgf-m, 3.5 lb-ft) Seat Bolt Seat rail Washer Frame Frame cover...

  • Page 118: Handlebar Controls

    CONSTRUCTIONS 12-3 HANDLEBAR CONTROLS 25 N·m (2.5 kgf-m, 18.0 lb-ft) Adhesive agent Adhesive agent 6 N·m (0.6 kgf-m, 4.5 lb-ft) 6 N·m (0.6 kgf-m, 4.5 lb-ft) REMOVAL • Remove the clutch lever. • Remove the engine stop switch 1. • Remove the clamps. •...

  • Page 119: Remounting

    NOTE: When tightening the handlebar clamp bolts, first tighten the bolts 1 and then tighten the bolts 2. • Apply SUZUKI SUPER GREASE to the throttle cable and their hole. " 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) •...
  • Page 120 CONSTRUCTIONS 12-5 • Align the punched mark D on the handlebars with the throttle holder matching surface. • Install the front brake master cylinder. (#14-13) • Inspect the throttle cable play. (#2-13) • Align the punched mark E on the handlebars with the clutch lever holder matching surface.

  • Page 121: Seat Rail, Drive Chain Control Roller

    12-6 CONSTRUCTIONS SEAT RAIL, DRIVE CHAIN CONTROL ROLLER 23 N·m (2.3 kgf-m, 16.5 lb-ft) 43 N·m (4.3 kgf-m, 31.0 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb-ft) 31 N·m (3.1 kgf-m, 22.5 lb-ft) 31 N·m (3.1 kgf-m, 22.5 lb-ft)
  • Page 122 FRONT AND REAR WHEELS 13-1 FRONT AND REAR WHEELS CONTENTS CONSTRUCTION ..................13- 2 FRONT WHEEL REMOVAL AND REASSEMBLY ........13- 3 FRONT WHEEL REMOVAL ..............13- 3 FRONT WHEEL REASSEMBLY ............13- 3 REAR WHEEL REMOVAL AND REASSEMBLY ........13- 3 REAR WHEEL REMOVAL ..............

  • Page 123: Construction

    13-2 FRONT AND REAR WHEELS CONSTRUCTION 110 N . m (11.0 kgf-m, 79.5 lb-ft) 10 N . m (1.0 kgf-m, 7.0 lb-ft) 32 N . m (3.2 kgf-m, 23.0 lb-ft) 35 N . m (3.5 kgf-m, 25.5 lb-ft) 10 N . m (1.0 kgf-m, 7.0 lb-ft)

  • Page 124: Front Wheel Removal And Reassembly

    FRONT AND REAR WHEELS 13-3 FRONT WHEEL REMOVAL AND REASSEMBLY FRONT WHEEL REMOVAL • Loosen the axle shaft holder bolts 1. • Remove the axle nut 2. • Loosen the axle shaft holder bolts 3. • Place the motorcycle on a block to lift front wheel off the ground.

  • Page 125: Rear Wheel Reassembly

    13-4 FRONT AND REAR WHEELS REAR WHEEL REASSEMBLY • Reassemble the rear wheel and axle shaft. Left Right • Adjust the drive chain slack. (#2-16) • Tighten the axle nut to the specified torque. " Rear axle nut: 110 N·m (11.0 kgf-m, 79.5 lb-ft) Chain adjuster washer FRONT AND REAR WHEEL INSPECTION SPACER AND DUST SEAL INSPECTION...

  • Page 126: Wheel Bearing Inspection

    FRONT AND REAR WHEELS 13-5 WHEEL BEARING INSPECTION • Turn the inner race by finger and inspect it for smooth move- ment. • Inspect the clearance between the outer race and wheel hub. • Inspect for bearing damage. WHEEL BEARING REMOVAL AND REASSEMBLY FRONT WHEEL BEARING REMOVAL •...

  • Page 127: Front Wheel Bearing Reassembly

    13-6 FRONT AND REAR WHEELS FRONT WHEEL BEARING REASSEMBLY • Apply grease to the bearings. Left • Reassemble the spacer and bearings with the special tools. Right ! 09924-84510: Bearing installer set 09913-70210: Bearing installer set NOTE: * Reassemble the left side (disc side) bearing first and then reassemble the right side bearing.

  • Page 128: Rear Sprocket Replacement

    FRONT AND REAR WHEELS 13-7 REAR SPROCKET REPLACEMENT • Tighten the nuts to the specified torque. " Rear sprocket nut: 32 N·m (3.2 kgf-m, 23.0 lb-ft) NOTE: Reassemble the rear sprocket as the letter on the sprocket sur- face faces outside.
  • Page 129 FRONT AND REAR BRAKES 14-1 FRONT AND REAR BRAKES CONTENTS CONSTRUCTION ..................14- 2 BRAKE FLUID AIR BLEEDING ..............14- 3 BRAKE FLUID REPLACEMENT ............... 14- 4 BRAKE PADS REPLACEMENT ............... 14- 5 FRONT BRAKE PADS ................ 14- 5 REAR BRAKE PADS ................14- 5 BRAKE DISC INSPECTION ..............

  • Page 130: Construction

    14-2 FRONT AND REAR BRAKES CONSTRUCTION 23 N·m (2.3 kgf-m, 10 N·m 16.5 lb-ft) (1.0 kgf-m, 7.0 lb-ft) 10 N·m (1.0 kgf-m, 7.0 lb-ft) 23 N·m (2.3 kgf-m, 23 N·m 16.5 lb-ft) (2.3 kgf-m, 18 N·m 16.5 lb-ft) (1.8 kgf-m, 13.0 lb-ft) 29 N·m (2.9 kgf-m, 21.0 lb-ft)

  • Page 131: Brake Fluid Air Bleeding

    FRONT AND REAR BRAKES 14-3 BRAKE FLUID AIR BLEEDING !"WARNING Brake fluid can be hazardous to humans and pets. Brake fluid is harmful or fatal if swallowed, and harm- ful if it comes in contact with your skin or eyes. Keep brake fluid away from children.

  • Page 132: Brake Fluid Replacement

    14-4 FRONT AND REAR BRAKES • Remove the reservoir cap. • Connect a transparent tube to the bleeder valve and set the other end into a receptacle. • Pour brake fluid up to the UPPER line. • Pump the brake lever/pedal until air bubbles stop coming out from the reservoir.

  • Page 133: Brake Pads Replacement

    FRONT AND REAR BRAKES 14-5 BRAKE PADS REPLACEMENT FRONT BRAKE PADS • Remove the cap 1 and pad mounting pin 2. • Remove the brake pads. NOTE: Replace the two brake pads as a set. • Fit the new brake pads into the caliper and tighten the pad mounting pin to the specified torque.

  • Page 134: Brake Disc Inspection

    14-6 FRONT AND REAR BRAKES BRAKE DISC INSPECTION • Measure the front and rear brake disc thickness. % Brake disc thickness Service limit (Front): 2.5 mm (0.10 in) (Rear): 3.5 mm (0.14 in) • Measure the front and rear brake disc runout. % Brake disc runout Service limit: 0.30 mm (0.012 in) CALIPER...

  • Page 135: Front Caliper Removal And Disassembly

    FRONT AND REAR BRAKES 14-7 FRONT CALIPER REMOVAL AND DISASSEMBLY • Drain brake fluid. ($14-4) • Place a rag under the brake hose union bolt 1 to catch spilled brake fluid. • Remove the caliper mounting bolts 2. • Remove the brake pads ($14-5) and spring from the cali- per.

  • Page 136: Rear Caliper Removal And Disassembly

    14-8 FRONT AND REAR BRAKES REAR CALIPER REMOVAL AND DISASSEM- • Place a block under the chassis tubes. • Remove the rear wheel. ($13-3) • Drain brake fluid. ($14-4) • Place a rag under the brake hose union bolt to catch spilled brake fluid.

  • Page 137: Caliper Cleaning

    • Fit the caliper brackets and pad springs. • Apply SUZUKI SILICONE GREASE to the caliper axles. & 99000-25100: SUZUKI SILICONE GREASE • Fit the brake pads. Tighten the brake pad mounting bolt tem- porarily.

  • Page 138: Rear Caliper Reassembly

    • Apply brake fluid to the piston seal and fit the piston seal and dust seal. • Apply SUZUKI SILICONE GREASE to the caliper axles. & 99000-25100: SUZUKI SILICONE GREASE • Tighten the caliper axle bolt 1 to the specified torque.

  • Page 139: Master Cylinder

    FRONT AND REAR BRAKES 14-11 MASTER CYLINDER !"WARNING Brake fluid can be hazardous to humans and pets. Brake fluid is harmful or fatal if swallowed, and harm- ful if it comes in contact with your skin or eyes. Keep brake fluid away from children. Call your doctor immediately if brake fluid is swallowed, and induce vomiting.

  • Page 140: Rear Master Cylinder Removal And Disassembly

    14-12 FRONT AND REAR BRAKES • Remove the diaphragm. • Remove the dust seal boot 1. • Remove the snap ring 2 with snap ring pliers. • Remove the washer 3, piston 4 and spring 5. ' 09900-06105: Snap ring pliers REAR MASTER CYLINDER REMOVAL AND DISASSEMBLY •...

  • Page 141: Master Cylinder Cleaning

    FRONT AND REAR BRAKES 14-13 MASTER CYLINDER CLEANING • Flush the master cylinder ports with pressurized air. • Wash the master cylinder bore and piston with fresh brake fluid. NOTE: Do not use gasoline or other cleaning solvents to wash the mas- ter cylinder parts.

  • Page 142: Rear Master Cylinder Reassembly

    • Remove the cotter pin 2, washer and pin. REASSEMBLY • Fit the return spring properly. • Apply SUZUKI SUPER GREASE to the brake pedal pivot bolt. ( 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) •...
  • Page 143 FRONT FORK AND STEERING 15-1 FRONT FORK AND STEERING CONTENTS CONSTRUCTION ..................15- 2 FRONT FORK TUNING ................15- 3 COMPRESSION DAMPING FORCE ADJUSTMENT ......15- 3 REBOUND DAMPING FORCE ADJUSTMENT ........15- 3 OIL QUANTITY MINOR ADJUSTMENT ..........15- 4 OIL CHANGE (Only for outer tube oil chamber) ......

  • Page 144: Construction

    15-2 FRONT FORK AND STEERING CONSTRUCTION 100 N . m (10.0 kgf-m, 72.5 lb-ft) 25 N . m (2.5 kgf-m, 18.0 lb-ft) 23 N . m (2.3 kgf-m, 16.5 lb-ft) 30 N . m (3.0 kgf-m, 21.5 lb-ft) 35 N . m (3.5 kgf-m, 25.5 lb-ft) 22 N .

  • Page 145: Front Fork Tuning

    FRONT FORK AND STEERING 15-3 FRONT FORK TUNING The front fork compression and rebound damping force, and oil level are adjustable for rider’s preference, rider’s weight and course condition. NOTE: * Break-in new front forks before attempting adjustment. * Be sure to adjust both right and left front forks equally. * Inspect the following items before attempting adjustment.

  • Page 146: Oil Quantity Minor Adjustment

    " Front fork oil quantity (With standard fork spring used) Standard: 362 ml (12.24/12.75 US/lmp oz) Oil quantity adjustable range: 321 – 415 ml (10.85/11.30 – 14.03/14.61 US/lmp oz) # 99000-99001-SS5: SUZUKI FORK OIL SS-05...

  • Page 147: Oil Change (Only For Outer Tube Oil Chamber)

    FRONT FORK AND STEERING 15-5 OIL CHANGE (Only for outer tube oil cham- ber) • Remove the front forks. (!15-11) • Thoroughly clean the fork before disassembly. CAUTION The fork oil quantity must be adjusted equally on both fork legs to provide equal performance. Scratches or other damage on the inner tube or on the oil seal lip will cause oil leak.
  • Page 148 15-6 FRONT FORK AND STEERING • Slide down the outer tube. • Pour the specified amount of fork oil into the outer tube. # 99000-99001-SS5: SUZUKI FORK OIL SS-05 Identification Oil quantity Parts No. Spring rate (Slit mark Oil quantity...

  • Page 149: Spring Change

    FRONT FORK AND STEERING 15-7 SPRING CHANGE • Remove the front forks. (!15-11) • Thoroughly clean the fork before disassembly. CAUTION The fork oil quantity must be adjusted equally on both fork legs to provide equal performance. Scratches or other damage the on inner tube or on the oil seal lip will cause oil leak.
  • Page 150 14.61 US/Imp oz) 326 – 420 ml 367 ml SOFT (11.02/11.48 – 14.20/ (12.40/12.92 US/Imp oz) 14.79 US/Imp oz) 316 – 410 ml 357 ml HARD (10.68/11.13 – 13.86/ (12.07/12.57 US/Imp oz) 14.44 US/Imp oz) # 99000-99001-SS5: SUZUKI FORK OIL SS-05...

  • Page 151: Front Fork Tuning Procedure

    FRONT FORK AND STEERING 15-9 FRONT FORK TUNING PROCEDURE Test ride the motorcycle and find out how the front suspension reacts on various types of surface. According to the symptom noticed, adjust the front fork to the best setting for rider and race track conditions. To adjust, attempt changing fork oil capacity and compression/rebound damping following the instructions below.

  • Page 152: Suspension Balance

    15-10 FRONT FORK AND STEERING SUSPENSION BALANCE Balancing the front to rear suspension properly is the most critical adjustment for suspension performance. If the front forks are adjusted harder than the rear suspension, such as changing to heavier front fork oil, stiffer compression and rebound setting, air pressure build up in the forks and so on, the front forks will collapse less on bumps.

  • Page 153: Front Fork

    FRONT FORK AND STEERING 15-11 FRONT FORK REMOVAL • Place a block under the chassis tubes. • Remove the front wheel. (!13-3) • Remove the handlebars. (!12-3) • Remove the fork protectors, brake hose guide and brake hose clamp. • Remove the front brake caliper. (!14-7) •...

  • Page 154: Disassembly

    15-12 FRONT FORK AND STEERING DISASSEMBLY • Set rebound and compression damper settings to the mini- mum settings (softest) before disassembling. Record the set- ting before turning the adjuster. • Thoroughly clean the fork before disassembly. CAUTION Scratches or other damage on the inner tube or on the oil seal lip will cause oil leak.
  • Page 155 FRONT FORK AND STEERING 15-13 • Clamp the axle holder 2 with a vise. Protect the axle holder with a rag when using a vise. • Loosen the center bolt 3 completely with a 21 mm socket wrench. & WARNING Clamping the axle holder too tight can damage it which will affect riding stability.
  • Page 156 15-14 FRONT FORK AND STEERING • With the outer tube compressed by hands, remove the special tool. CAUTION Removing the locknut 4 and pushing the inner rod thread into the damper rod will damage the inner rod oil seal. Do not remove the locknut 4 from the inner rod. •...
  • Page 157 FRONT FORK AND STEERING 15-15 INNER TUBE • Separate the inner tube out of the outer tube. • Remove the slide bushing from the inner tube. • Remove the following parts from the inner tube. Guide bushing 1 Seal retainer 2 Oil seal 3 Stopper ring 4 Dust seal 5...

  • Page 158: Inspection

    15-16 FRONT FORK AND STEERING • Remove the compression damper unit from the sub-tank. NOTE: Slowly compress the inner rod until it stops so that the compres- sion damper unit can be removed easily. CAUTION Disassembling the compression damper unit can lead to trouble.
  • Page 159 FRONT FORK AND STEERING 15-17 INNER TUBE AND OUTER TUBE • Inspect the inner tube for scratches. If it has scratches, replace it with a new one. • Inspect the outer tube for dent. If it is dented all the way to the inner side, replace it with a new one.

  • Page 160: Reassembly

    15-18 FRONT FORK AND STEERING SLIDE BUSHING AND GUIDE BUSHING Inspect the “teflon coating metals” (slide bushing and guide bushing) for wear or damage. If they are worn or damaged, replace them with new ones. Inspect the metal particles on the “teflon coating metals”. If they are not clean, clean them with a nylon brush and fork oil.
  • Page 161 Clean each threaded part before installing. • With the damper rod in fully extended position, pour the spec- ified amount of fork oil. " Fork oil quantity (Inside the damper rod): 180 ml (6.08/6.34 US/lmp oz) # 99000-99001-SS5: SUZUKI FORK OIL SS-05...
  • Page 162 15-20 FRONT FORK AND STEERING • Apply fork oil to the O-rings and bushing on the compression damper unit. • With the damper rod held immovable in fully extended posi- tion, gently install the compression damper unit to the sub- tank.
  • Page 163 FRONT FORK AND STEERING 15-21 • Force out the remaining oil (discharged oil) using compressed air completely. • With the damper rod in horizontal position, move the inner rod by hand to inspect it if operating smoothly. If the inner rod is not extend, repeat the “COMPRESSION DAMPER UNIT”...
  • Page 164 15-22 FRONT FORK AND STEERING • Clamp the axle holder with a vise. Protect the axle holder with a rag when using a vise. & WARNING Clamping the axle holder too tight can damage it which will affect riding stability. Do not clamp the axle holder too tight.

  • Page 165: Installation

    • Pour the specified amount of fork oil into the outer tube. " Oil quantity (When standard fork spring is used): 362 ml (12.24/12.75 US/lmp oz) # 99000-99001-SS5: SUZUKI FORK OIL SS-05 • Raise the outer tube and temporarily tighten the fork cap bolt (sub-tank).
  • Page 166 15-24 FRONT FORK AND STEERING • Tighten the fork upper clamp bolts to the specified torque. % Fork upper clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) • Tighten the fork cap bolt (sub-tank) to the specified torque. $ 09941-53630 : Front fork top cap wrench % Fork cap bolt: 35 N·m (3.5 kgf-m, 25.5 lb-ft) •...

  • Page 167: Steering

    FRONT FORK AND STEERING 15-25 STEERING REMOVAL • Remove the front wheel. (!13-3) • Remove the front number plate. • Remove the handlebar holder bolts and remove the handle- bars. • Remove the brake caliper. • Remove the brake hose guide. •...

  • Page 168: Inspection

    15-26 FRONT FORK AND STEERING • Remove the steering nut with the special tools. $ 09940-14911: Steering nut socket wrench 09940-14960: Attachment • Remove the lower bracket. INSPECTION • Inspect the bearing races for wear. • Inspect the needle bearings for wear. •...

  • Page 169: Installation

    FRONT FORK AND STEERING 15-27 • Fit the upper and lower outer races with the special tools. $ 09941-34513: Steering outer race and swingarm bearing installer 09924-84510: Bearing installer INSTALLATION • Apply grease to the bearings. • Fit the steering stem, upper bearing and steering stem nut. •...
  • Page 170 REAR SUSPENSION 16-1 REAR SUSPENSION CONTENTS CONSTRUCTION ..................16- 2 REAR SUSPENSION TUNING ..............16- 3 LOW SPEED COMPRESSION DAMPING FORCE ADJUSTMENT .. 16- 3 HIGH SPEED COMPRESSION DAMPING FORCE ADJUSTMENT .. 16- 3 REBOUND DAMPING FORCE ADJUSTMENT ........16- 4 SPRING PRE-LOAD ADJUSTMENT ..........

  • Page 171: Construction

    16-2 REAR SUSPENSION CONSTRUCTION 80 N . m (8.0 kgf-m, 58.0 lb-ft) 80 N . m (8.0 kgf-m, 58.0 lb-ft) 60 N . m 60 N . m (6.0 kgf-m, (6.0 kgf-m, 43.5 lb-ft) 43.5 lb-ft) 70 N . m (7.0 kgf-m, 50.5 lb-ft)

  • Page 172: Rear Suspension Tuning

    REAR SUSPENSION 16-3 REAR SUSPENSION TUNING The rear suspension compression and rebound damping force, and spring pre-load are adjustable for rider’s preference, rider’s weight and course condition. NOTE: * Break-in the rear suspension when riding with a new rear cushion unit. (!1-10) * Inspect the following items before attempting adjustment.

  • Page 173: Rebound Damping Force Adjustment

    16-4 REAR SUSPENSION REBOUND DAMPING FORCE ADJUSTMENT • Turn the adjuster 1 clockwise until it stops (full hard position). NOTE: Do not force the adjuster past the stopped position, or you may damage the adjuster. • Turn the adjuster 1 counterclockwise the specified clicks so that the punched mark A will be aligned with the punched mark B.

  • Page 174: Rear Suspension Tuning Procedure

    REAR SUSPENSION 16-5 REAR SUSPENSION TUNING PROCEDURE • Select the rear suspension according to the rider’s weight and preference by referring to the table below. Spring Part No. Spring rate Marking paint Set-length adjustable range 48 N/mm 62211-37FA0 Black (4.8 kgf/mm) Soft 50 N/mm 62211-37FB0...

  • Page 175: Rear Suspension

    16-6 REAR SUSPENSION REAR SUSPENSION After the sag measurement has been set between 101 mm (3.97 in), test ride the motorcycle and adjust the suspension for the rider and track conditions referring to the guide below. SYMPTOM SECTION ADJUSTMENT PROCEDURE Feels too hard overall •...

  • Page 176: Suspension Balance

    REAR SUSPENSION 16-7 SUSPENSION BALANCE Balancing the front to rear suspension properly is the most critical adjustment for suspension performance. If the front forks are adjusted harder than the rear suspension, such as changing to heavier front fork oil, stiffer compression and rebound setting, air pressure build up in the forks and so on, the front forks will collapse less on bumps.

  • Page 177: Spring Removal

    16-8 REAR SUSPENSION • Remove the rear shock absorber lower mounting bolt and nut. • Remove the rear shock absorber upper mounting bolt and nut. • Remove the rear shock absorber. SPRING REMOVAL • Remove the rear shock absorber unit from the frame. (!16-7) •...

  • Page 178: Bearing Replacement

    REAR SUSPENSION 16-9 • Inspect the spacers and dust seals for damage. • Inspect the bearing for excessive play and smooth movement. BEARING REPLACEMENT • Remove the rear shock absorber unit from the frame. (!16-7) • Remove the spacers. • Remove the needle roller bearings 1. •...

  • Page 179: Spring Installation

    • Install the spacers A and B. A for Right side B for Left side $ 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) SPRING INSTALLATION • Fit the locknut, adjuster, spring, spring seat and stopper ring.

  • Page 180: Oil Replacement Procedure

    REAR SUSPENSION 16-11 OIL REPLACEMENT PROCEDURE TOOLS AND EQUIPMENT • Following tools and equipment are required to perform oil replacement. 1 Screwdriver or small punch 7 Rags 2 Vise* 8 Nitrogen tank 3 Drain Pan 9 Filler Hose and Nozzle 4 Oilcan 0 Regulator Assembly 5 Beaker...
  • Page 181 16-12 REAR SUSPENSION OIL REPLACEMENT PROCEDURE • Remove the rear shock absorber unit from the frame. Clean and dry it. (!16-7) • Remove the spring from the rear shock absorber unit. (!16-8) NOTE: Inspect the rear shock absorber unit for oil leak. Turn the rebound damping force adjuster screw counterclock- wise until it stops, so that the rear suspension oil can be poured easily.
  • Page 182 Be sure to extend the rod after filling the oil. • Tilt the shock absorber unit as shown and pour the fresh rear suspension oil fully into the reservoir tank. 99000-99001-S25: SUZUKI REAR SUSPENSION OIL SS-25 " Oil capacity: Approx. 380 ml (12.84/13.38 US/Imp oz) •...

  • Page 183: Rear Shock Absorber Disassembly And Inspection

    16-14 REAR SUSPENSION • Reinstall the compression adjuster assembly 1. NOTE: Replace the O-rings on the compression adjuster assembly with new ones. % Compression adjuster assembly: 30 N·m (3.0 kgf-m, 21.5 lb-ft) • Fill the rear shock absorber unit with nitrogen gas to 981 kPa (9.8 kgf/cm , 139.5 psi).
  • Page 184 REAR SUSPENSION 16-15 • Vise the rear shock absorber unit in inverted position. • Depress the bump rubber fully to protect the damper rod from the tool. • Evenly hammer the stopper 1 with the screwdriver or equiva- lent and remove it from the rear shock absorber body. •...

  • Page 185: Rear Shock Absorber Reassembly

    • Fit the stopper to the shock absorber body. • Fill the specified rear suspension oil in the rear shock absorber. (!16-13) 99000-99001-S25: SUZUKI REAR SUSPENSION OIL SS-25 " Oil capacity: Approx. 380 ml (12.84/13.38 US/Imp oz) • Reinstall the compression adjuster assembly. (!16-14) •...

  • Page 186: Swingarm

    REAR SUSPENSION 16-17 SWINGARM DISASSEMBLY • Place a block under chassis tubes. • Remove the rear wheel. (!13-3) • Remove the chain guide 1. • Remove the brake hose guide 2. • Remove the rear caliper assembly 3 from the swingarm. •...

  • Page 187: Inspection

    16-18 REAR SUSPENSION • Remove the chain buffer. • Remove the spacers. Dust seal Washer Thrust bearing INSPECTION • Inspect the chain buffer for damage and excessive wear. • Measure the pivot shaft runout with a dial gauge and V- blocks.

  • Page 188: Bearing Replacement

    BEARING REPLACEMENT • Remove the bearings with the special tool. # 09921-20240: Bearing remover set • Apply SUZUKI SUPER GREASE to the bearings. $ 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Press the new bearings with the special tools.

  • Page 189: Rear Suspension Linkage

    16-20 REAR SUSPENSION • Tighten the rear cushion lever nut to the specified torque. % Rear cushion lever nut: 80 N·m (8.0 kgf-m, 58.0 lb-ft) • Reassemble the brake pedal. (!14-14) • Reassemble the rear caliper assembly. • Install the rear brake hose guides. •...

  • Page 190: Bearing Removal

    • Remove the bearings with the special tool. # 09921-20240: Bearing remover set BEARING INSTALLATION • Apply grease to the bearings. $ 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Press the bearings with the special tool and suitable size socket wrench.
  • Page 191 16-22 REAR SUSPENSION • Tighten the cushion lever, cushion rod and swingarm nuts to the specified torque. Left Right 5 mm 4 mm 4 mm 4 mm % Tightening torque: A: 60 N·m (6.0 kgf-m, 43.5 lb-ft) B: 60 N·m (6.0 kgf-m, 43.5 lb-ft) C: 80 N·m (8.0 kgf-m, 58.0 lb-ft) D: 80 N·m (8.0 kgf-m, 58.0 lb-ft) E: 80 N·m (8.0 kgf-m, 58.0 lb-ft)
  • Page 192 REAR SUSPENSION 16-23 Left Right CAUTION Improperly reassembled rear suspension linkage bolts can interfere with suspension move- ment and damage the rear suspension linkage. * Make sure that the rear shock absorber rebound damping adjuster on the bottom bracket of the rear shock absorber is located to the right side.
  • Page 193 ELECTRICAL SYSTEM 17-1 ELECTRICAL SYSTEM CONTENTS ELECTRICAL CIRCUIT ................17- 2 INSPECTION ..................... 17- 2 IGNITION SYSTEM PEAK VOLTAGE ..........17- 2 IGNITION COIL ................... 17- 4 CDI UNIT ..................... 17- 4 STATOR COIL ..................17- 5...

  • Page 194: Electrical Circuit

    17-2 ELECTRICAL SYSTEM ELECTRICAL CIRCUIT Throttle position sensor Engine stop switch B/Br Magneto W/Bl W/Bl Ignition coil CDI unit Spark plug Carburetor solenoid COLOR CODE O/W: Orange with White tracer Black B/R: Black with Red tracer Green B/W: Black with White tracer Orange W/Bl: White with Blue tracer...
  • Page 195 ELECTRICAL SYSTEM 17-3 Measure the ignition system peak voltage in the following proce- dure: • Connect the multi circuit tester with the peak volt adaptor as follows. (See table below.) • Measure the highest peak voltage by depressing the kick starter lever more than 3 times forcefully.

  • Page 196: Ignition Coil

    17-4 ELECTRICAL SYSTEM IGNITION COIL • Remove the seat and fuel tank. (!3-2) • Remove the ignition coil 1. Measure the ignition coil electrical resistance. White/Blue – Approx. 0.17 – 0.46 Ω Ω Ω Ω Primary Black/White Plug cap – Approx.

  • Page 197: Stator Coil

    ELECTRICAL SYSTEM 17-5 Unit: Approx. V Positive + probe pin (Diode terminal) ❍ (1.130 ❍ (0.936 ❍ (0.294 ❍ (0.627 ❍ (0.618 ❍ (1.174 ❍ (0.624 ❍ (0.411 ❍ (0.0 – ❍ (0.179 — – 1.523) – 1.523) – 0.894) –...
  • Page 198 TROUBLESHOOTING 18-1 TROUBLESHOOTING CONTENTS TROUBLESHOOTING ................18- 2 ENGINE ....................18- 2 CHASSIS ..................... 18- 5...
  • Page 199 18-2 TROUBLESHOOTING TROUBLESHOOTING ENGINE Complaint Possible Cause Remedy Engine does not start Fuel deterioration Replace or hard to start No fuel flow to the carburetor • Fuel valve clogged Clean • Fuel hose clogged Clean or replace • Fuel tank cap breather hose clogged Clean •...
  • Page 200 TROUBLESHOOTING 18-3 Complaint Possible Cause Remedy Engine runs poorly in Exhaust valve maladjustment Adjust low speed range Wide spark plug gap Adjust or replace Carburetor air screw maladjustment Adjust Incorrect carburetor fuel level Adjust Improper jet needle size Replace Incorrect ignition timing Adjust CDI unit malfunction Replace...
  • Page 201 18-4 TROUBLESHOOTING Complaint Possible Cause Remedy Overheating Low engine coolant level Replenish Engine coolant leak Repair Too lean air/fuel mixture Adjust Incorrect ignition timing Adjust Water pump malfunction Adjust or replace Cylinder head carbon deposits Clean Exhaust pipe carbon deposits Clean or replace Improper spark plug heat range Replace...
  • Page 202 Improper air bleeding Bleed air Dirty pads and disc Clean Brake fluid leak Repair Brake noise Brake pads worn Replace Brake disc worn Replace Dirty brake pads and disc Clean * An optional spring is available at your SUZUKI dealer.
  • Page 203 SERVICE DATA 19-1 SERVICE DATA CONTENTS SERVICE DATA ..................19- 2 CYLINDER + PISTON + PISTON RING ..........19- 2 CONROD + CRANKSHAFT ..............19- 2 CLUTCH ....................19- 2 RADIATOR + COOLANT ..............19- 3 TRANSMISSION + DRIVE CHAIN ............19- 3 CARBURETOR ...................

  • Page 204: Service Data

    19-2 SERVICE DATA SERVICE DATA CYLINDER + PISTON + PISTON RING ITEM STD/SPEC. LIMIT Piston to cylinder clearance 0.045 – 0.055 mm 0.120 mm (0.0018 – 0.0022 in) (0.0047 in) Cylinder bore 66.400 – 66.415 mm Nicks or (2.6142 – 2.6148 in) scratches Measure 20 mm (0.79 in) from the top surface Piston diam.

  • Page 205: Radiator + Coolant

    SERVICE DATA 19-3 RADIATOR + COOLANT ITEM STD/SPEC. LIMIT Radiator cap valve release 95 – 125 kPa — (0.95 – 1.25 kgf/cm , 14 – 18 psi) pressure Engine coolant type Use a anti-freeze & Summer coolant compatible with aluminum radiator, mixed with distilled water —...

  • Page 206: Electrical

    19-4 SERVICE DATA ELECTRICAL ITEM STD/SPEC. NOTE Spark plug Type NGK: BR8EG 0.5 – 0.6 mm (0.020 – 0.024 in) 0.17 – 0.46 Ω Ignition coil resistance Primary W/Bl – B/W Secondary 13 – 20 kΩ W/Bl – Plug cap 78 –...

  • Page 207: Tire

    Front fork spring rate 4.4 N/mm — (0.44 kgf/mm) Front fork oil type SUZUKI FORK OIL SS-05 or an equivalent fork oil — Front fork oil capacity (each leg) OUTER: 362 ml (12.24/12.75 US/Imp oz) — INNER: 180 ml (6.08/6.34 US/Imp oz)

  • Page 208: Fuel + Oil

    19-6 SERVICE DATA FUEL + OIL ITEM STD/SPEC. NOTE Fuel type Use only unleaded gasoline of at least 90 pump For Canada octane (R/2 + M/2 method). Use only unleaded gasoline of at least 95 octane. For other coun- (Research method) tries Fuel tank capacity 8.0 L...

  • Page 209: Tightening Torque

    SERVICE DATA 19-7 TIGHTENING TORQUE ENGINE PART N·m kgf-m lb-ft Cylinder head nuts 18.0 Magneto rotor nut 40.0 Cylinder nuts 27.5 Clutch sleeve hub nut 65.0 Crankcase bolt Primary drive gear bolt 50.5 Gearshift cam bolt 23.5 2.35 18.0 Gearshift pawl lifter screw Exhaust valve shaft arm bolt Kick starter lever bolt 16.5...

  • Page 210: Tightening Torque Chart

    19-8 SERVICE DATA TIGHTENING TORQUE CHART For other bolts and nuts not listed in the table, refer to this chart. Bolt Conventional or “4” marked bolt “7” marked or crown headed bolt Diameter A N·m kgf-m lb-ft N·m kgf-m lb-ft (mm) 0.15 0.23...

  • Page 211: Special Tools

    SERVICE DATA 19-9 SPECIAL TOOLS 09900-20101 09900-20203 09900-20205 09900-06105 09900-06107 Vernier calipers Micrometer Micrometer Snap ring plier Snap ring plier (150 mm) (50 – 75 mm) (0 – 25 mm) 09900-20602 09900-20605 09900-20607 09900-20508 Dial gauge Dial caliper (1/100 Dial gauge 09900-20701 Cylinder gauge set (1/1 000 mm)
  • Page 212 19-10 SERVICE DATA 09925-18011 09930-30113 Steering bearing 09930-11960 Flywheel rotor 09930-40113 09940-14911 installer Torx wrench, T20 remover Rotor holder Steering nut wrench 09940-14960 09940-52861 09941-34513 Steering nut socket 09940-34581 Front fork oil seal Steering race 09941-50111 wrench Attachment F installer set installer Bearing remover 09941-53630...

  • Page 213: Wiring Diagram

    SERVICE DATA 19-11 WIRING DIAGRAM IGNITION COIL CDI UNIT CARBURETOR SOLENOID ENGINE STOP SWITCH : Pickup THROTTLE coil POSITION SENSOR MAGNETO WIRE COLOR Black Green Blue Orange White Yellow B/R: Black with Red tracer B/W: Black with White tracer B/Y: Black with Yellow tracer O/W: Orange with White tracer R/W:...

  • Page 214: Wire, Cable And Hose Routing

    19-12 SERVICE DATA WIRE, CABLE AND HOSE ROUTING WIRE HARNES ROUTING Clamp Engine stop switch lead wire Ignition coil coupler Frame Clamp CDI unit Engine stop switch Wiring harness Clamp Clamp Exhaust valve breather hose Carburetor solenoid lead wire Throttle position sensor lead wire Clamp Throttle cable Magneto...

  • Page 215: Cable Routing

    SERVICE DATA 19-13 CABLE ROUTING...

  • Page 216: Carburetor Hose And Water Hose Routing

    19-14 SERVICE DATA CARBURETOR HOSE AND WATER HOSE ROUTING...
  • Page 217 SERVICE DATA 19-15 No.1 radiator joint hose Radiator inlet hose Face the white marking paint to the left side. Left side Backward Upward Face the white Right side marking paint to the right side. Radiator No.2 radiator joint hose outlet hose Backward Radiator overflow hose Radiator...

  • Page 218: Front Brake Hose Routing

    19-16 SERVICE DATA FRONT BRAKE HOSE ROUTING Front brake master cylinder Washer Front brake hose Hose guide After touching the brake hose union to the stopper, tighten the union bolt to the specified torque. Front brake hose Clamp Clamp the upper difference portion in brake hose diameter.

  • Page 219: Rear Brake Hose Routing

    SERVICE DATA 19-17 REAR BRAKE HOSE ROUTING...

  • Page 220: Handlebar Set-Up

    19-18 SERVICE DATA HANDLEBAR SET-UP Quick adjuster Turn to tighten Turn to tighten the clutch cable tension. the clutch cable tension. Turn to loosen Turn to loosen the clutch cable tension. the clutch cable tension. When the movement is felt heavier, clean this and apply grease.

  • Page 221: Muffler Set-Up

    SERVICE DATA 19-19 MUFFLER SET-UP...

  • Page 222: Specifications

    19-20 SERVICE DATA SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ............2 175 mm (86.5 in) Overall width ............840 mm (33.1 in) Overall height ............1 280 mm (50.4 in) Wheelbase ............1 470 mm (57.9 in) Ground clearance ..........350 mm (13.8 in) Seat height............

  • Page 223: Chassis

    SERVICE DATA 19-21 CHASSIS Front suspension..........Telescopic, pneumatic/coil spring, oil damped, Rear suspension ..........Link type, Steering angle ............. 45° (right & left) Caster..............27° 30’ Trail..............115 mm (4.53 in) Turning radius............2.3 m (7.5 ft) Front brake ............Disc brake Rear brake............

  • Page 224: Spare Parts

    19-22 SERVICE DATA SPARE PARTS ITEM PART NAME PART NUMBER Q’TY O-RING, CYLINDER HEAD NO. 1 11147-37F00 O-RING, CYLINDER HEAD NO. 2 11148-37F00 GASKET, CYL COVER, NO. 1 11233-37F20 GASKET, CYL COVER, NO. 2 11234-37F20 GASKET, CYL COVER, NO. 3 11238-37F20 GASKET, CYLINDER 11241-37F20...
  • Page 225 WARNING Failure to follow these safety precautions may increase your risk of injury: ¹ ¹ Wear a helmet, eye protection, and bright protective clothing. Don’t ride after consuming alcohol or other drugs. ¹ This owner’s service manual contains important safety information.

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