Suzuki RM125 Owner's Service Manual
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Suzuki RM125 Owner's Service Manual

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RM125
OWNER'S SERVICE MANUAL
Part No. 99011-36F56-01A
April, 2006
EN
TK

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Summary of Contents for Suzuki RM125

  • Page 1 RM125 OWNER’S SERVICE MANUAL Part No. 99011-36F56-01A April, 2006...
  • 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 Please read this manual and follow its instructions This manual is presented as a means whereby you carefully. To emphasize special information, the can maintain your RM125 in top working condition symbol  and the words WARNING, CAUTION at all times. Your riding skill and the maintenance and NOTE have special meanings.
  • Page 4 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 5: Serial Number Location

    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 6 WARNINGS FOR SERVICING  WARNING  WARNING Never run the engine indoors or in a Fuel can catch on fire if you do not handle garage. Exhaust gas contains carbon mon- it properly. Gasoline vapors can catch fire oxide, a gas that is colorless and odorless easily.

  • Page 7: Replacement Parts

    NOTE: installing a circlip. Use of replacement parts which are not equivalent • Use special tools where specified. in quality to genuine SUZUKI parts can lead to per- • Use genuine SUZUKI parts and recommended formance problems and damage. oil.
  • Page 8 SYMBOL DEFINITION SYMBOL DEFINITION Torque control required. Use SUZUKI FORK OIL SS-05 or Data beside it indicates specified equivalent fork oil. torque. 99000-99001-SS5 Use SUZUKI REAR SUSPENSION OIL Apply oil. Use engine oil or transmission SS-25 or equivalent rear suspension oil.
  • Page 9 GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE TROUBLESHOOTING MACHINE TUNING ENGINE REMOVAL AND INSTALLATION CYLINDER, PISTON AND EXHAUST VALVE CLUTCH KICK STARTER GEARSHIFTING TRANSMISSION AND CRANKSHAFT FUEL SYSTEM COOLING SYSTEM ELECTRICAL SYSTEM FRONT AND REAR WHEELS FRONT AND REAR BRAKES FRONT FORK AND STEERING REAR SUSPENSION SERVICING INFORMATION...

  • Page 10: Table Of Contents

    GENERAL INFORMATION 1-1 GENERAL INFORMATION CONTENTS LOCATION OF PARTS ................1- 2 FUEL AND OIL RECOMMENDATION ............1- 3 OPERATING INSTRUCTIONS ..............1- 4 STARTING THE ENGINE ..............1- 4 STOPPING THE ENGINE ..............1- 4 TRANSMISSION ..................1- 5 BREAK-IN (RUNNING-IN) ................

  • Page 11: Location Of Parts

    1-2 GENERAL INFORMATION LOCATION OF PARTS 1 Clutch lever 2 Engine stop switch 3 Front brake fluid reservoir 4 Throttle grip 5 Front brake lever 6 Fuel tank cap 7 Fuel valve 8 Carburetor starter knob 9 Gearshift lever 0 Rear brake fluid reservoir A Rear brake pedal B Kick starter lever C Front suspension compression damp-...

  • Page 12: Fuel And Oil Recommendation

    (R/2 + M/2 method)..For USA and Canada Use only unleaded gasoline of at least 95 octane (Research method)....For other countries. Engine oil: SUZUKI CCI SUPER 2-CYCLE MOTOR LUBRI- CANT or equivalent Two Cycle Racing Lubricant ..........For USA...

  • Page 13: Operating Instructions

    1-4 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 starter knob 1.

  • Page 14: Transmission

    GENERAL INFORMATION 1-5 TRANSMISSION This motorcycle has a 6-speed transmission. Neutral is located between low and 2nd. Engage first gear by pressing the lever down from the neutral position. You can shift into higher gears by lifting on the shift lever once for each gear. When neutral is desired, press or lift the lever to a position halfway between low and 2nd gear.
  • Page 15 – MEMO –...
  • Page 16 PERIODIC MAINTENANCE 2-1 PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE ................ 2- 3 INSPECTION BEFORE PRACTICE ............2- 3 INSPECTION BEFORE RACE (All items of inspection before practice above plus) ......2- 3 PERIODIC MAINTENANCE CHART ............ 2- 4 SPARK PLUG ....................2- 6 AIR CLEANER .....................
  • Page 17 PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS SPROCKET INSPECTION ..............2-17 DRIVE CHAIN GUIDE, BUFFER, TENSIONER ROLLER ......2-17 DRIVE CHAIN GUIDE ................2-17 DRIVE CHAIN GUIDE BUFFER ............2-18 DRIVE CHAIN TENSIONER ROLLER ..........2-18 BRAKES ...................... 2-18 BRAKE FLUID LEVEL ................. 2-18 BRAKE PAD ..................

  • Page 18: Periodic Maintenance

    PERIODIC MAINTENANCE 2-3 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 •...

  • Page 19: Periodic Maintenance Chart

    2-4 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 2-5 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: Spark Plug

    2-6 PERIODIC MAINTENANCE SPARK PLUG • Inspect the spark plug condition, electrode color, carbon deposits, 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 22: Air Cleaner

    PERIODIC MAINTENANCE 2-7 AIR CLEANER AIR CLEANER ELEMENT REMOVAL • Remove the seat. (5-3) • Remove the air cleaner box lid. (2-8) • Remove the wing nut 1. • Remove the element 2 from the element holder. WASHING • Fill a washing pan large enough to hold the element with a non-flammable cleaning solvent A.

  • Page 23: Transmission Oil

    2-8 PERIODIC MAINTENANCE • Install the air cleaner box lid properly as shown. NOTE: Running the engine without the air cleaner box lid can vary the carburetion. Do not run the engine without the air cleaner box lid. Cap to the front. Air cleaner box front wall NOTE:...

  • Page 24: Transmission Oil Level Inspection And Replenishment

    PERIODIC MAINTENANCE 2-9 WARNING New and used oil and solvent can be hazardous. Chil- dren and pets may be harmed by swallowing new or used oil or solvent. Repeated, prolonged contact with used engine oil may cause skin cancer. Brief contact with used oil or solvent may irritate skin.

  • Page 25: Engine Coolant

    2-10 PERIODIC MAINTENANCE 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 26: Engine Coolant Replenishment

    PERIODIC MAINTENANCE 2-11 ENGINE COOLANT REPLENISHMENT • Use an anti-freeze and Summer engine coolant which is com- patible with aluminum radiator, mixed with distilled water at the ratio of 50:50. NOTE: The radiator, cylinder and cylinder head are made of aluminum alloy.

  • Page 27: Clutch Cable

    2-12 PERIODIC MAINTENANCE CLUTCH CABLE Adjust the clutch cable play as follows: MAJOR ADJUSTMENT • Loosen lock-nut 1. • Turn adjuster 2 so the clutch lever has 10 – 15 mm (0.4 – 0.6 in) play at the clutch lever end before pressure is felt. •...

  • Page 28: Fuel Hose

    PERIODIC MAINTENANCE 2-13 • Apply oil to the throttle cable. • Apply grease to the throttle cable spool.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) FUEL HOSE • Inspect the fuel hose for damage and fuel leakage. If any defects are found, the fuel hose must be replaced.

  • Page 29: Cylinder Head, Cylinder And Piston

    2-14 PERIODIC MAINTENANCE CYLINDER HEAD, CYLINDER AND PISTON CYLINDER HEAD • Remove the cylinder head. (6-3) • Remove carbon deposits from the combustion chamber sur- face. • Inspect for pinholes, cracks and other damage. CYLINDER • Remove the cylinder. (6-4) •...

  • Page 30: Exhaust Valve

    • Fit the glass wool 1 and the black frontal pipe to the alumi- num case. • Tighten three bolts. NOTE: To seal between the black frontal pipe flange and the aluminum case, apply SUZUKI BOND to the contact area of the flange.  99000-31140: SUZUKI BOND “1207B”...

  • Page 31: Drive Chain And Sprockets

    2-16 PERIODIC MAINTENANCE DRIVE CHAIN AND SPROCKETS DRIVE CHAIN SLACK • Place the motorcycle on the side stand. • Inspect the drive chain slack at the middle point between the drive chain buffer and rear sprocket.  Drive chain slack: 40 – 50 mm (1.6 – 2.0 in) 0 –...

  • Page 32: Sprocket Inspection

    • 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 equivalent to the link plates and rollers. • Reassemble the drive chain.

  • Page 33: Drive Chain Guide Buffer

    2-18 PERIODIC MAINTENANCE DRIVE CHAIN GUIDE BUFFER • Inspect the drive chain guide buffer 1 for wear and cracks. NOTE: The drive chain can touch the swingarm directly if the chain guide buffer is worn out. This will cause drive chain and swing- arm damage.

  • Page 34: Brake Pad

    PERIODIC MAINTENANCE 2-19 BRAKE PAD Wear limit • Inspect the brake pads for wear. If the brake pads are worn, replace them with new ones. (15-5) NOTE: * Pump the brake lever/pedal several times to restore the brake Wear limit pads after replacing the brake pads.

  • Page 35: Front Fork

    2-20 PERIODIC MAINTENANCE FRONT FORK • Move the front fork up and down several times and inspect for smooth movement. • Inspect for damage and oil leaks. • Inspect the bolts and nuts for tightness. • Place a stand under the chassis tube to lift the front wheel off the ground.

  • Page 36: Spoke Nipple And Rim Lock

    PERIODIC MAINTENANCE 2-21 SPOKE NIPPLE AND RIM LOCK • Inspect the spokes for tension by squeezing the spoke nip- ples. • Retighten the spoke nipples with a spoke nipple wrench so as all spokes have same tension.  Spoke nipple: 4 N·m (0.4 kgf-m, 3.0 lb-ft) CAUTION Improperly tightening of the spoke nipples can dam- age the wheel.

  • Page 37: Steering

    2-22 PERIODIC MAINTENANCE STEERING • Inspect the steering by moving the front fork up and down, and right and left. If the steering has play or binds, inspect steering stem head nut tightness and steering bearings. (16-20)

  • Page 38: Lubrication

    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 39 – MEMO –...

  • Page 40: Troubleshooting

    TROUBLESHOOTING 3-1 TROUBLESHOOTING CONTENTS TROUBLESHOOTING ................. 3- 2 ENGINE ....................3- 2 CHASSIS ....................3- 5...

  • Page 41: Troubleshooting

    3-2 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 42 TROUBLESHOOTING 3-3 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 43 3-4 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 44 TROUBLESHOOTING 3-5 CHASSIS Complaint Possible Cause Remedy Heavy handling Steering stem nut overtightened Adjust Steering head bearings damaged or rusted Replace Steering stem distortion Replace Front wheel wobbling Loose spoke nipples Adjust Wheel distortion Replace Front wheel bearing damage Replace Incorrect axle tightening torque Retighten Rear wheel wobbling...
  • Page 45 – MEMO –...
  • Page 46 MACHINE TUNING 4-1 MACHINE TUNING CONTENTS CARBURETOR TUNING ................4- 2 PRINCIPLES OF CARBURETOR TUNING .......... 4- 2 CARBURETOR TUNING IN PRACTICE ..........4- 6 FRONT FORK TUNING ................4- 9 COMPRESSION DAMPING FORCE ADJUSTMENT ......4- 9 REBOUND DAMPING FORCE ADJUSTMENT ........4- 9 OIL QUANTITY MINOR ADJUSTMENT ..........

  • Page 47: Carburetor Tuning

    Riders who are not familiar with the operation and ing of them for proper carburetor tuning. jetting procedures of the MIKUNI 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 48 MACHINE TUNING 4-3 As shown below, each tuning part 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 carburetor can supply correct air/fuel mixture to the engine in any range because of the overlapping adjustable range of the each part.
  • Page 49 4-4 MACHINE TUNING NEEDLE CLIP POSITION JET NEEDLE O.D. of needle Lean Needle clip Rich Taper portion Clip The jet needle is linked to the throttle valve by means of the needle clip. Its lower part is tapered and it has five grooves cut in the upper part where the needle clip fits.
  • Page 50 MACHINE TUNING 4-5 THROTTLE STOP SCREW The throttle stop screw determines the full close position of the throttle valve and should be adjusted in the following proce- dures. • Loosen the throttle stop screw lock-nut. • Adjust the throttle stop screw as follows: * Turn in (to raise the throttle valve).

  • Page 51: Carburetor Tuning In Practice

    4-6 MACHINE TUNING 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 52 MACHINE TUNING 4-7 JUDGING AIR/FUEL MIXTURE INCLUDED PARTS AND OPTIONAL PARTS For proper carburetor tuning, it is necessary to Main jet know how to judge the air/fuel mixture made in the Air/fuel carburetor; whether too rich, too lean or properly SIZE P/NO mixture...
  • Page 53 4-8 MACHINE TUNING Cable holder and washer Ex. Main jet #370 ITEM P/NO Color If air/fuel mixture is rich, replace it with Cable holder * 13518-36F20 Yellow #360 main jet. If air/fuel mixture is lean, Washer * 13394-36F20 replace it with #380 main jet. The cable holder and washer must be used as a 3 Adjustment of intermediate system set.

  • Page 54: Front Fork Tuning

    MACHINE TUNING 4-9 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 55: Oil Quantity Minor Adjustment

     Front fork oil quantity (With standard fork spring used) Standard: 357 ml (12.07 / 12.57 US/lmp oz) Oil quantity adjustable range: 314 – 408 ml (10.61/11.06 – 13.79/14.37 US/lmp oz)  99000-99001-SS5: SUZUKI FORK OIL SS-05 (or equivalent fork oil)

  • Page 56: Oil Change (Only For Outer Tube Oil Chamber)

    MACHINE TUNING 4-11 OIL CHANGE (Only for outer tube oil chamber) • Remove the front forks. (16-4) • 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 57 4-12 MACHINE TUNING • Slide down the outer tube. • Pour the specified amount of fork oil into the outer tube.  99000-99001-SS5: SUZUKI FORK OIL SS-05 (or equivalent fork oil) Identification Oil quantity Parts No. Spring rate (Slit mark...

  • Page 58: Spring Change

    MACHINE TUNING 4-13 SPRING CHANGE • Remove the front forks. (16-4) • 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 59 314 – 408 ml 357 ml (10.61/11.06 – 51171-37FD0 (12.07/12.57 13.79/14.37 US/Imp oz) US/Imp oz) 309 – 403 ml 352 ml (10.44/10.88 – Hard 51171-37FC0 (11.90/12.39 13.62/14.19 US/Imp oz) US/Imp oz)  99000-99001-SS5: SUZUKI FORK OIL SS-05 (or equivalent fork oil)

  • Page 60: Front Fork Tuning Procedure

    MACHINE TUNING 4-15 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 61: Rear Suspension Tuning

    4-16 MACHINE TUNING 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. (1-5) * Inspect the following items before attempting adjustment.

  • Page 62: Spring Pre-Load Adjustment

    MACHINE TUNING 4-17 SPRING PRE-LOAD ADJUSTMENT (For E-19, 000) (For E-19, 000) • Place a block under the chassis tube. • Remove the silencer and rear frame assembly. (17-3) • Loosen the lock-nut 1 with the special tool.  09910-60611: Universal clamp wrench •...

  • Page 63: Rear Suspension Tuning Procedure

    4-18 MACHINE TUNING REAR SUSPENSION TUNING PROCEDURE • Adjust 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 46 N/mm 62211-36F60 Green (4.6 kgf/mm) Soft 48 N/mm 62211-37FH0...
  • Page 64 MACHINE TUNING 4-19 After the sag measurement has been set between 95 mm (3.74 in) to 105 mm (4.13 in), test ride the motor- cycle and adjust the suspension for the rider and track conditions referring to the guide below. SYMPTOM SECTION ADJUSTMENT PROCEDURE...

  • Page 65: Suspension Balance

    4-20 MACHINE TUNING 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 66: Engine Removal And Installation

    ENGINE REMOVAL AND INSTALLATION 5-1 ENGINE REMOVAL AND INSTALLATION CONTENTS EXTERIOR PARTS ..................5- 2 ENGINE REMOVAL AND INSTALLATION ..........5- 3 REMOVAL ..................... 5- 3 INSTALLATION ..................5- 7...

  • Page 67: Exterior Parts

    5-2 ENGINE REMOVAL AND INSTALLATION EXTERIOR PARTS 10 N·m (1.0 kgf-m, 7.0 lb-ft) For E-03, 28 For E-19, 000 10 N . m 1.0 kgf-m 7.0 lb-ft 5 N·m (0.5 kgf-m, 3.5 lb-ft) 10 N . m 1.0 kgf-m 7.0 lb-ft 10 N .

  • Page 68: Engine Removal And Installation

    ENGINE REMOVAL AND INSTALLATION 5-3 ENGINE REMOVAL AND INSTALLATION REMOVAL • Drain transmission oil. (2-9) • Drain engine coolant. (12-3) • Remove the seat. • Turn the fuel valve lever to the “OFF” position. • Disconnect the fuel hose 1. •...
  • Page 69 5-4 ENGINE REMOVAL AND INSTALLATION • Remove the exhaust pipe. • Remove the exhaust pipe gasket 3. • Remove the radiator covers 4 and mounting bolts (LH and RH). • Disconnect the radiator hoses 5 6 7. • Disconnect the spark plug cap 8. •...
  • Page 70 ENGINE REMOVAL AND INSTALLATION 5-5 • Disconnect the magneto lead wire coupler 9 and clamp. • Unclamp the magneto lead wire and breathers hoses from the frame. • Remove the drive chain by removing the clip 0. • Remove the cotter pins A. •...
  • Page 71 5-6 ENGINE REMOVAL AND INSTALLATION • Unhook and extract the clutch cable D. NOTE: Loosen the clutch cable adjuster when disconnecting. (2-12) • Remove the engine mounting bolts and plates. • Remove the swingarm pivot nut E and washer. • Extract three quarters of the swingarm pivot shaft so as to keep the swingarm in position.

  • Page 72: Installation

    * Apply THREAD LOCK SUPER to the engine mounting bolt 3.  99000-32110: THREAD LOCK SUPER “1322” (or equivalent thread lock) • Apply grease to the brake pedal pivot bolt.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the spring. (18-15) • Install the brake pedal.
  • Page 73 5-8 ENGINE REMOVAL AND INSTALLATION • Reassemble the drive chain clip so the slit end faces opposit the direction of rotation. Direction of travel • Fit the projection of carburetor to the depression of intake pipe. • Install a new O-ring 6 and connector rubber 7 to the exhaust pipe.

  • Page 74: Cylinder, Piston And Exhaust Valve

    CYLINDER, PISTON AND EXHAUST VALVE 6-1 CYLINDER, PISTON AND EXHAUST VALVE CONTENTS CONSTRUCTION ..................6- 2 ENGINE TOP END ..................6- 3 CYLINDER HEAD REMOVAL .............. 6- 3 CYLINDER REMOVAL ................6- 3 PISTON REMOVAL ................6- 4 EXHAUST VALVE REMOVAL .............. 6- 5 CYLINDER HEAD INSPECTION ............

  • Page 75: Construction

    6-2 CYLINDER, PISTON AND EXHAUST VALVE CONSTRUCTION 17.5 N . m (1.75 kgf-m, 12.5 lb-ft) 25 N . m 45 N . m (2.5 kgf-m, 18.0 lb-ft) (4.5 kgf-m, 32.5 lb-ft) 1216 25 N . m (2.5 kgf-m, 18.0 lb-ft) 1216 4.5 N .

  • Page 76: Engine Top End

    CYLINDER, PISTON AND EXHAUST VALVE 6-3 ENGINE TOP END CYLINDER HEAD REMOVAL • Remove the seat. (5-3) • Remove the fuel tank. (5-3) • Drain engine coolant. (12-3) • Disconnect the radiator hose 1. • Disconnect the spark plug cap 2 and remove the spark plug ...

  • Page 77: Piston Removal

    6-4 CYLINDER, PISTON AND EXHAUST VALVE • Remove the exhaust valve rod bolt 7 using the pin A as a stopper. NOTE: The pin A is one of the included parts. • Remove the cylinder nuts diagonally. • Remove the cylinder 8. •...

  • Page 78: Exhaust Valve Removal

    CYLINDER, PISTON AND EXHAUST VALVE 6-5 • Remove the conrod small end bearing 4. EXHAUST VALVE REMOVAL • Remove the cylinder head and cylinder. (6-3, -4) • Remove the exhaust valve shaft stop retainer 1. • Remove the breather hoses 2. •...

  • Page 79: Cylinder Head Inspection

    6-6 CYLINDER, PISTON AND EXHAUST VALVE • Remove the side valves and spacers. CYLINDER HEAD INSPECTION • Remove carbon deposits from the cylinder head. • Inspect the cylinder head for cracks around the spark plug hole. • Inspect for cylinder head distortion. ...

  • Page 80: Piston And Piston Ring Inspection

    CYLINDER, PISTON AND EXHAUST VALVE 6-7 • Measure the cylinder bore for wear with a cylinder gauge 20 mm (0.8 in) from the top surface. NOTE: The cylinder bore must be measured perpendicular to the crank- shaft axis direction.  Cylinder bore 20 mm (0.8 in) Standard: 54.000 –...

  • Page 81: Exhaust Valve Inspection

    6-8 CYLINDER, PISTON AND EXHAUST VALVE • Measure the piston ring free end gap.  Piston ring free end gap Service Limit: 3.4 mm (0.13 in)  09900-20101: Vernier calipers PISTON-TO-CYLINDER CLEARANCE As a result of the previous measurement, if the piston to cylinder clearance exceeds the following limit, replace both cylinder and piston.

  • Page 82: Piston Ring And Piston Reassembly

    CYLINDER, PISTON AND EXHAUST VALVE 6-9 • Fit the piston pin and bearing into the conrod small end and inspect the play. • Inspect the bearing for smooth movement. PISTON RING AND PISTON REASSEMBLY • Apply engine oil to the piston ring and piston ring groove. •...

  • Page 83: Cylinder Reassembly

    6-10 CYLINDER, PISTON AND EXHAUST VALVE • Install the exhaust valve assembly to the cylinder. • Inspect the main and side valves for smooth movement. • Inspect if the side valves are closed when the main valve is lowered and, at the same time, see if the side valvs are open when the main valve is lifted.
  • Page 84 • Install a new gasket and tighten the exhaust valve rod cover bolts. • Apply grease to new O-rings and install them to the cylinder.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the cylinder head. NOTE: Apply Bond to the stud bolt threads when assembling the removed stud bolts into the cylinder.

  • Page 85: Exhaust Valve Governor Removal And Disassembly

    6-12 CYLINDER, PISTON AND EXHAUST VALVE EXHAUST VALVE GOVERNOR REMOVAL AND DISASSEMBLY • Drain transmission oil. (2-9) • Drain engine coolant. (12-3) • Remove the exhaust pipe. (5-3, -4) • Remove the exhaust valve rod bolt. (6-4) • Remove the right crankcase cover. (8-3) •...

  • Page 86: Exhaust Valve Governor Inspection

    CYLINDER, PISTON AND EXHAUST VALVE 6-13 EXHAUST VALVE GOVERNOR INSPECTION • Inspect hte bearings for abnormal noise, wear and damage. • Replace the bearing if there is anything unusual. • Inspect the governer for wear and damage. • Replace the governer if there is anything unusual. •...
  • Page 87 6-14 CYLINDER, PISTON AND EXHAUST VALVE • Tighten the exhaust valve rod bolt. (6-11)  Exhaust valve rod bolt: 4.5 N·m (0.45 kgf-m, 3.0 lb-ft) • Reassemble the exhaust pipe. (5-8) • Transmission oil level (2-9) • Engine coolant level (2-10) •...
  • Page 88 CLUTCH 7-1 CLUTCH CONTENTS CONSTRUCTION ..................7- 2 CLUTCH PLATE ..................7- 3 REMOVAL ..................... 7- 3 INSPECTION ..................7- 4 REASSEMBLY ..................7- 5 PRIMARY DRIVEN GEAR AND CLUTCH SLEEVE HUB ......7- 6 REMOVAL ..................... 7- 6 INSPECTION ..................7- 7 REASSEMBLY ..................

  • Page 89: Construction

    7-2 CLUTCH CONSTRUCTION 4.5 N . m (0.45 kgf-m, 3.0 lb-ft) 70 N . m (7.0 kgf-m, 50.5 lb-ft) No. 1 drive plate (Black paint) No. 2 drive plate (Purple paint)

  • Page 90: Clutch Plate

    CLUTCH 7-3 CLUTCH PLATE REMOVAL • Drain transmission oil. (2-9) • Remove the rear brake pedal. (5-5) • Remove the clutch cover 1. • Loosen the bolts diagonally and remove them. • Remove the clutch springs. • Remove the pressure plate 2. •...

  • Page 91: Inspection

    7-4 CLUTCH INSPECTION DRIVE PLATE • Measure the drive plate thickness.  Drive plate thickness Service Limit: 2.42 mm (0.095 in)  09900-20101: Vernier calipers • Inspect the drive plates for wear, distortion and discoloration. • Measure the drive plate claw width. ...

  • Page 92: Reassembly

     Clutch spring bolt: 4.5 N·m (0.45 kgf-m, 3.0 lb-ft) • Replace the O-ring with a new one. • Apply grease to the O-ring.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Fit the clutch outer cover 2 and tighten the bolts diagonally.

  • Page 93: Primary Driven Gear And Clutch Sleeve Hub

    7-6 CLUTCH PRIMARY DRIVEN GEAR AND CLUTCH SLEEVE HUB REMOVAL • Remove the clutch outer cover. • Remove the pressure plate and clutch plates. (7-3) • Flatten the lock washer 1. • Hold the clutch sleeve hub with the special tool and loosen the nut 2.

  • Page 94: Inspection

    CLUTCH 7-7 INSPECTION • Inspect the clutch sleeve hub and primary driven gear assem- bly for wear and cracks. • Inspect the kick starer idle gear, needle bearing and spacer for damage and wear. REASSEMBLY • Apply transmission oil to the spacer 1 and needle bearing 2. •...
  • Page 95 • Reassemble the clutch plates and pressure plate. (7-5) • Replace the O-ring with a new one. • Apply grease to the O-ring.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Fit the clutch outer cover and tighten the bolts diagonally.

  • Page 96: Clutch Release Camshaft

    CLUTCH 7-9 CLUTCH RELEASE CAMSHAFT REMOVAL • Remove the magneto rotor and stator. (13-8) • Loosen the clutch cable adjuster and unhook the clutch cable. (5-6) • Remove the clutch release camshaft 1. INSPECTION CLUTCH RELEASE CAMSHAFT • Inspect the clutch release camshaft for abnormal deflection and damage.
  • Page 97 – MEMO –...
  • Page 98 KICK STARTER 8-1 KICK STARTER CONTENTS CONSTRUCTION ..................8- 2 REMOVAL ....................8- 3 INSPECTION ....................8- 4 OIL SEAL ....................8- 4 KICK STARTER ..................8- 4 KICK STARTER IDLE GEAR ..............8- 4 REASSEMBLY .................... 8- 5 INSPECTION AFTER REASSEMBLY ..........8- 6...

  • Page 99: 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 100: Removal

    KICK STARTER 8-3 REMOVAL • Drain transmission oil. (2-9) • Drain engine coolant. (12-3) • Remove the brake pedal. (5-5) • Remove the kick starter lever. • Disconnect the radiator hose 1. • Remove the crankcase cover. • Remove the clutch and primary driven gear assembly. (7-3, -6) •...

  • Page 101: Inspection

    KICK STARTER INSPECTION OIL SEAL • Inspect the oil seal for oil leakage and damage. • Remove the oil seal using the special tool.  09913-50121: Oil seal remover • Install the oil seal using the special tool.  09913-70210: Bearing installer set KICK STARTER •...

  • Page 102: Reassembly

    KICK STARTER 8-5 REASSEMBLY Reassemble the kick starter assembly in the reverse order of disassembly. Pay attention to the following points: • Apply transmission oil to the kick starter shaft. • Install the kick starter drive gear 1 and washer to the kick starter shaft.

  • Page 103: Inspection After Reassembly

    KICK STARTER • Install the kick starter assembly to the crankcase. Hook the return spring 2. • Reassemble the kick idle gear 5. • Reassemble the primary driven gear assembly and clutch. (7-5, -7) • Install the crankcase cover.  Crankcase cover bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft) •...

  • Page 104: Gearshifting

    GEARSHIFTING 9-1 GEARSHIFTING CONTENTS CONSTRUCTION ..................9- 2 REMOVAL ....................9- 3 INSPECTION ....................9- 5 REASSEMBLY .................... 9- 6...

  • Page 105: Construction

    9-2 GEARSHIFTING CONSTRUCTION 23 N . m (2.3 kgf-m, 16.5 lb-ft) 24 N . m (2.4 kgf-m, 17.5 lb-ft) 10 N . m (1.0 kgf-m, 7.0 lb-ft)

  • Page 106: Removal

    GEARSHIFTING 9-3 REMOVAL • Drain transmission oil. (2-9) • Drain engine coolant. (12-3) • Remove the gearshift lever 1. NOTE: Mark the gearshift shaft head at which the gearshift lever slit set for correct reinstallation. • Remove the right crankcase cover. (8-3) •...
  • Page 107 9-4 GEARSHIFTING • Remove the gearshift cam bolt 9 and stopper plate 0. • Remove the gearshift arm stopper bolt A and washer. • Remove the gearshift cam stopper B and spring C. • Remove the gearshift return spring D by removing the snap ring.

  • Page 108: Inspection

    GEARSHIFTING 9-5 INSPECTION • Inspect the gearshift shaft 1 for bends and damage. • Inspect the return spring 2 for damage. • Inspect the pawls 3, pins 4 and springs 5 for damage.

  • Page 109: Reassembly

    9-6 GEARSHIFTING REASSEMBLY • Temporarily install the spring 1, washer 2 and gearshift cam stopper 3. • Hook the spring 1 to the projection A. • Tighten the gearshift cam stopper bolt.  Gearshift cam stopper bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) •...
  • Page 110 GEARSHIFTING 9-7 • Fit the springs 6, pins 7 and pawls 8 to the gearshift cam driven gear 9. Wider side D of pawls should be positioned outside. • With the pawls held in pushed position, install the pawl lifter •...
  • Page 111 9-8 GEARSHIFTING • Align the center teeth on the gearshift shaft with the center teeth on the gearshift cam shifter. • Reassemble the clutch and crankcase cover. (7-5, -7, 8-6) • Install the gearshift lever.  Gearshift lever bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) •...

  • Page 112: Transmission And Crankshaft

    TRANSMISSION AND CRANKSHAFT 10-1 TRANSMISSION AND CRANKSHAFT CONTENTS CONSTRUCTION ..................10- 2 ENGINE BOTTOM END ................10- 3 PRIMARY DRIVE GEAR REMOVAL ..........10- 3 CRANKCASE SEPARATION ............. 10- 4 TRANSMISSION REMOVAL .............. 10- 4 CRANKSHAFT REMOVAL ..............10- 5 TRANSMISSION INSPECTION ............

  • Page 113: Construction

    10-2 TRANSMISSION AND CRANKSHAFT CONSTRUCTION 70 N . m (7.0 kgf-m, 50.5 lb-ft)

  • Page 114: Engine Bottom End

    TRANSMISSION AND CRANKSHAFT 10-3 ENGINE BOTTOM END • Dismount the engine. (5-3) NOTE: The following parts must be removed before disassembling the engine bottom side (crankcase). • Remove the gearshift lever. (9-3) • Remove the kick starter lever. (8-3) • Remove the cylinder head, cylinder and piston. (6-3, -4) •...

  • Page 115: Crankcase Separation

    10-4 TRANSMISSION AND CRANKSHAFT CRANKCASE SEPARATION • Remove the engine sprocket spacer 1 and two O-rings 2. • 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.

  • Page 116: Crankshaft Removal

    TRANSMISSION AND CRANKSHAFT 10-5 • Remove the driveshaft assembly 6 and countershaft assem- bly 7. CRANKSHAFT REMOVAL • Remove the crankshaft with the special tool.  09920-13120: Crankcase separating tool CAUTION Be careful not to damage the thread part of the crank- shaft.

  • Page 117: Crankshaft Inspection

    10-6 TRANSMISSION AND CRANKSHAFT • Measure the gearshift fork thickness with a vernier calipers.  Gearshift fork thickness Standard: 4.80 – 4.90 mm (0.189 – 0.193 in)  09900-20101: Vernier calipers • Measure the gearshift fork groove width with a vernier cali- pers.

  • Page 118: Crankshaft Runout

    TRANSMISSION AND CRANKSHAFT 10-7 • Measure the crankshaft runout with V-blocks and dial gauge.  Crankshaft runout Service Limit: 0.05 mm (0.002 in)  09900-20607: Dial gauge (1/100 mm) 09900-20701: Magnetic stand 09900-21304: V-block NOTE: * Place the crankshaft on to the V-blocks so that it becomes hor- izontally.
  • Page 119 • Install new oil seal using the special tool. • Apply grease to each oil seal lip.  09913-70210: Bearing installer set  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) NOTE: Be sure to check the direction of the crankshaft bearing oil seals before fitting them.

  • Page 120: Bearing Inspection, Removal And Installation

    TRANSMISSION AND CRANKSHAFT 10-9 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 the bearings 1 to 4 by hitting out from the other side using the special tool.

  • Page 121: Crankshaft Installation

    10-10 TRANSMISSION AND CRANKSHAFT • Remove the bearings 9 and 0 using the special tool.  09917-50410: Bearing remover • Remove the bearing A using the special tools.  09921-20200: Bearing remover 09930-30104: Sliding shaft • Install the bearings with the special tool. ...

  • Page 122: Transmission Reassembly

    TRANSMISSION AND CRANKSHAFT 10-11 TRANSMISSION REASSEMBLY NOTE: Seat the circlip in the groove and locate its end as shown in the Thrust illustration. Sharp edge • Apply transmission oil to the following parts: driveshaft, countershaft, transmission gears, bearings. • Reassemble the driveshaft 1 and countershaft 2 with gears installed.

  • Page 123: Crankcase Reassembly

    • Inspect the crankshaft, countershaft and driveshaft for smooth movement. • Apply grease to the oil seal lip and new O-rings. • Fit the O-rings 1 and spacer 2 to the driveshaft.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease)

  • Page 124: Primary Drive Gear Installation

    TRANSMISSION AND CRANKSHAFT 10-13 PRIMARY DRIVE GEAR INSTALLATION • Reassemble the clutch release camshaft. (7-9) • Reassemble the stator and magneto rotor. (13-9) • Install the washer and primary drive gear. NOTE: The washer is directional. Assemble the washer 1 as shown in the illustration.
  • Page 125 – MEMO –...

  • Page 126: Fuel System

    FUEL SYSTEM 11-1 FUEL SYSTEM CONTENTS CARBURETOR ..................11- 2 CONSTRUCTION ................11- 2 REMOVAL AND DISASSEMBLY ............11- 3 CLEANING ..................11- 7 INSPECTION ..................11- 7 REASSEMBLY AND REMOUNTING ..........11- 8 CARBURETOR SOLENOID ..............11-10 REMOVAL AND INSPECTION ............11-10 REASSEMBLY ..................

  • Page 127: Carburetor

    11-2 FUEL SYSTEM CARBURETOR CONSTRUCTION 10 N . m (1.0 kgf-m, 7.0 lb-ft)

  • Page 128: Removal And Disassembly

    FUEL SYSTEM 11-3 REMOVAL AND DISASSEMBLY • Disconnect the throttle position sensor coupler and solenoid coupler. • Open the clamp. • Disconnect the fuel hose. (5-3) • Loosen the carburetor clamp screws and remove the carbure- tor. • Drain fuel by removing the drain plug. •...
  • Page 129 11-4 FUEL SYSTEM • Remove the cable holder 5 and jet needle 6. • Remove the fuel hose 7, air vent hoses 8 and overflow hoses 9. • Remove the float chamber. • Remove the holder 0. • Remove the floats A and needle valve B. •...
  • Page 130 FUEL SYSTEM 11-5 • Remove the power jet G. • Remove the starter knob H. • Remove the lock-nut and throttle stop screw I. • Remove the air screw J and spring. • Remove the filter K. • Remove the solenoid L. NOTE: Prior to disassembly, mark the sensor’s original position with a paint or scribe for accurate reinstallation.
  • Page 131 11-6 FUEL SYSTEM • Flatten the plate M. • Remove the throttle lever shaft bolt. • Remove the dust seal N. • Remove the throttle lever shaft O. • Remove the throttle lever P, spacer Q and return spring R.

  • Page 132: Cleaning

    FUEL SYSTEM 11-7 CLEANING WARNING Some carburetor cleaning chemicals, especially dip- type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical man- ufacturer’s instructions on proper use, handling and storage. • Clean all jets with a spray-type carburetor cleaner and dry them using compressed air.

  • Page 133: Reassembly And Remounting

    11-8 FUEL SYSTEM NEEDLE VALVE INSPECTION If foreign matter is caught between the valve seat and the nee- dle valve, the fuel will continue flowing and overflow. If the valve seat and needle valve are worn beyond the permissible limits, similar trouble will occur.
  • Page 134 FUEL SYSTEM 11-9 • Fit the projection on the carburetor body to the depression of the intake pipe. After reinstalling the carburetor body assembly, inspect the fol- lowings. • Throttle position sensor adjustment (11-11) • Idle adjustment (4-5) • Throttle cable play (2-12) •...

  • Page 135: Carburetor Solenoid

    11-10 FUEL SYSTEM CARBURETOR SOLENOID REMOVAL AND INSPECTION • Remove the carburetor solenoid 1. Make sure the coupler 2 is connected. • Connect the tachometer sensor. • Shift the transmission into neutral. • Start the engine. • Inspect if the solenoid valve switches according to the follow- ing engine RPM.

  • Page 136: Throttle Position Sensor

    FUEL SYSTEM 11-11 THROTTLE POSITION SENSOR INSPECTION THROTTLE POSITION SENSOR INPUT VOLTAGE • Disconnect the throttle position sensor coupler 1. • Shift the transmission into neutral. • Start the engine. • Measure the throttle position sensor input voltage with the B/Br B/Br multi circuit tester.

  • Page 137: Reed Valve

    11-12 FUEL SYSTEM REED VALVE REMOVAL • Remove the carburetor. (11-3) • Remove the intake pipe and reed valve. INSPECTION • Inspect the reeds for damage. • Inspect the reed valve stoppers for damage. • Inspect the valve seat rubber for damage. NOTE: Be careful not to damage the removed reed valve assembly.

  • Page 138: Cooling System

    COOLING SYSTEM 12-1 COOLING SYSTEM CONTENTS CONSTRUCTION ..................12- 2 COOLING CIRCUIT ................... 12- 3 INSPECTION ..................12- 3 ENGINE COOLANT ................... 12- 3 REPLACEMENT .................. 12- 3 RADIATOR ....................12- 4 REMOVAL ................... 12- 4 INSPECTION ..................12- 4 INSTALLATION ...................

  • Page 139: Construction

    12-2 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 140: Cooling Circuit

    COOLING SYSTEM 12-3 COOLING CIRCUIT INSPECTION • Remove the radiator cap. • Connect the tester 1 to the filler.  WARNING Do not remove the radiator cap when the engine is hot. • Give a pressure of about 120 kPa (1.2 kgf/cm , 17.1 psi) and see if the system holds this pressure for 10 seconds.

  • Page 141: Radiator

    12-4 COOLING SYSTEM RADIATOR REMOVAL • Remove the seat and fuel tank. (5-3) • Drain engine coolant. (12-3) • Remove the radiator covers 1. (LH & RH) • Remove the hoses. • Remove the radiators. INSPECTION RADIATOR • Visually inspect the radiator for damage. •...

  • Page 142: Water Pump

    COOLING SYSTEM 12-5 WATER PUMP REMOVAL • Drain the engine coolant. (12-3) • Drain the transmission oil. (2-9) • Remove the kick starter lever. (8-3) • Remove the brake pedal. (5-5) • Disconnect the radiator hose 1. • Remove the water pump cover 2. •...

  • Page 143: Reassembly

    • Apply THREAD LOCK SUPER to the outer surface of the oil seal.  99000-32110: THREAD LOCK SUPER “1322” (or equivalent thread lock) • Press the oil seal with the suitable size socket wrench. • Apply grease to the oil seal lip.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease)
  • Page 144 COOLING SYSTEM 12-7 • Press the bearing with the special tool.  09913-70210: Bearing installer set NOTE: When installing the bearing the stamped mark on the bearing must face outside. • Hold the water pump shaft with a wrench and tighten the impeller to the specified torque.
  • Page 145 12-8 COOLING SYSTEM • Reassemble the clutch cover and water pump cover. After reinstalling the water pump, check the followings. • Kick starter lever (8-6) • Brake pedal (2-19, 5-7) • Transmission oil level (2-9) • Engine coolant level (2-10)

  • Page 146: Electrical System

    ELECTRICAL SYSTEM 13-1 ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING ............... 13- 2 CONNECTOR ..................13- 2 COUPLER ................... 13- 2 SEMI-CONDUCTOR EQUIPPED PART ..........13- 2 USING THE MULTI-CIRCUIT TESTER ..........13- 2 SWITCH ....................13- 2 LOCATION OF ELECTRICAL COMPONENTS ........13- 3 CONSTRUCTION ..................

  • Page 147: Cautions In Servicing

    13-2 ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTOR • When connecting a connector, be sure to push it in until a click is felt. Click • Inspect the connector for corrosion, contamination and break- age in its cover. COUPLER Click • With a lock type coupler, be sure to release the lock when dis- connecting, and push in fully to engage the lock when con- necting.

  • Page 148: Location Of Electrical Components

    ELECTRICAL SYSTEM 13-3 LOCATION OF ELECTRICAL COMPONENTS 1 Engine stop switch 3 CDI unit 2 Ignition coil 4 Magneto, pick-up coil...

  • Page 149: Construction

    13-4 ELECTRICAL SYSTEM CONSTRUCTION 35 N . m (3.5 kgf-m, 25.5 lb-ft) ELECTRICAL CIRCUIT Throttle position sensor Engine stop switch B/Br B/Br B/Bl B/Bl Magneto W/Bl W/Bl Ignition coil CDI unit Y Y Y Spark plug Carburetor solenoid Wire color: B: Black B/Bl: Black with Blue B/R: Black with Red tracer...

  • Page 150: Troubleshooting (No Spark Or Poor Spark)

    ELECTRICAL SYSTEM 13-5 TROUBLESHOOTING (No spark or poor spark) Step 1 1) Check the ignition system couplers for poor connections. Is there connection in the ignition system couplers? Go to Step 2. Poor connection of couplers Step 2 1) Measure the peak voltage of ignition coil. (13-6) Is the peak voltage OK? Go to Step 3.

  • Page 151: Ignition System

    13-6 ELECTRICAL SYSTEM Step 8 1) Measure the exciter coil and charge coil resistance. (13-7) Is the exciter coil and charge coil OK? Faulty CDI Faulty magneto IGNITION SYSTEM IGNITION SYSTEM PEAK VOLTAGE INSPECTION • Remove the seat and fuel tank. (5-3) •...

  • Page 152: Ignition Coil Inspection

    ELECTRICAL SYSTEM 13-7 IGNITION COIL INSPECTION • Remove the seat and fuel tank. (5-3) • Disconnect the ignition coil lead wire coupler 1. Measure the ignition coil electrical resistance.  White/Blue – 0.17 – 0.70 Ω Primary Black/White Plug cap – Secondary 13 –...

  • Page 153: Magneto Rotor And Stator Removal

    13-8 ELECTRICAL SYSTEM MAGNETO ROTOR AND STATOR REMOVAL • Remove the seat and fuel tank. (5-3) • Disconnect the magneto lead wire coupler and clamp. • Remove the bolts and magneto cover 1. • Remove the nut with a special tool. ...

  • Page 154: Magneto Rotor And Stator Reassembly

    ELECTRICAL SYSTEM 13-9 MAGNETO ROTOR AND STATOR REASSEMBLY • Fit the key 1 into the crankshaft. • Align the line on the stator with the line on the crankcase to set the ignition timing correctly. • Install the magneto rotor. •...
  • Page 155 – MEMO –...

  • Page 156: Front And Rear Wheels

    FRONT AND REAR WHEELS 14-1 FRONT AND REAR WHEELS CONTENTS CONSTRUCTION ..................14- 2 FRONT WHEEL ..................14- 3 REMOVAL ................... 14- 3 INSPECTION ..................14- 3 BEARING REPLACEMENT ..............14- 4 DISC PLATE REPLACEMENT ............14- 5 INSTALLATION ................... 14- 5 REAR WHEEL ...................

  • Page 157: Construction

    14-2 FRONT AND REAR WHEELS CONSTRUCTION 100 N . m (10.0 kgf-m, 72.5 lb-ft) 10 N . m (1.0 kgf-m, 7.0 lb-ft) 30 N . m (3.0 kgf-m, 21.5 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 158: Front Wheel

    FRONT AND REAR WHEELS 14-3 FRONT WHEEL REMOVAL • Place the motorcycle on a block to lift front wheel off the ground. • Remove the front axle nut 1. • Loosen the left axle holder bolts 2. • Loosen the right axle holder bolts 3. •...

  • Page 159: Bearing Replacement

    14-4 FRONT AND REAR WHEELS WHEEL RIM • Measure the wheel rim runout with the dial gauge.  Service Limit: 2.0 mm (0.08 in) ... axial and radial  09900-20607: Dial gauge (1/100 mm) 09900-20701: Magnetic stand WHEEL BEARING • Turn the inner race by finger and inspect it for smooth move- ment.

  • Page 160: Disc Plate Replacement

    • Reassemble the bearings with the special tools. • Fit the dust seals and apply grease to their lips.  09941-34513: Steering race installer 09924-84521: Bearing installer set  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) NOTE: Left Right * Install the left side (disc side) bearing first and then the right side bearing.

  • Page 161: Rear Wheel

    14-6 FRONT AND REAR WHEELS REAR WHEEL REMOVAL • Place the motorcycle on a block to lift the rear wheel off the ground. • Remove rear axle nut 1 and washer 2. • Remove the rear axle shaft 3 and chain adjuster washers 4. •...

  • Page 162: Bearing Replacement

    • Fit the dust seals and apply grease to their lips.  09941-34513: Steering race installer 09913-70210: Bearing installer set  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) NOTE: * Install the right side (disc side) bearing first and then the left...

  • Page 163: Rear Sprocket Replacement

    14-8 FRONT AND REAR WHEELS REAR SPROCKET REPLACEMENT • Remove the rear sprocket. NOTE: Install the rear sprocket as the letter on the sprocket surface faces outside. • Tighten the bolts/nuts to the specified torque.  Rear sprocket bolt/nut: 30 N·m (3.0 kgf-m, 21.5 lb-ft) INSTALLATION Left Right...

  • Page 164: Front And Rear Brakes

    FRONT AND REAR BRAKES 15-1 FRONT AND REAR BRAKES CONTENTS CONSTRUCTION ..................15- 2 BRAKE FLUID AIR BLEEDING ..............15- 3 BRAKE FLUID REPLACEMENT ............... 15- 4 BRAKE PADS REPLACEMENT ............... 15- 5 FRONT BRAKE PADS ................ 15- 5 REAR BRAKE PADS ................15- 5 BRAKE DISC INSPECTION ..............

  • Page 165: Construction

    15-2 FRONT AND REAR BRAKES CONSTRUCTION 10 N·m 23 N·m (1.0 kgf-m, 7.0 lb-ft) (2.3 kgf-m, 16.5 lb-ft) 10 N·m (1.0 kgf-m, 7.0 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb-ft) 23 N·m (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 166: Brake Fluid Air Bleeding

    FRONT AND REAR BRAKES 15-3 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 167: Brake Fluid Replacement

    15-4 FRONT AND REAR BRAKES NOTE: Do not release the brake lever/pedal while the bleeder valve is opened. • Replenish brake fluid to the UPPER line when the brake fluid level drops below LOWER line. • Tighten the air bleeder valve. ...

  • Page 168: Brake Pads Replacement

    FRONT AND REAR BRAKES 15-5 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. •...
  • Page 169 15-6 FRONT AND REAR BRAKES • Apply SUZUKI SILICONE GREASE to the O-ring.  99000-25100: SUZUKI SILICONE GREASE • Fit the new brake pads into the caliper. • Tighten the brake pad mounting pin to the specified torque.  Brake pad mounting pin: 18 N·m (1.8 kgf-m, 13.0 lb-ft) NOTE: * Inspect not to pinch the O-ring of brake pad mounting pin.

  • Page 170: Brake Disc Inspection

    FRONT AND REAR BRAKES 15-7 BRAKE DISC INSPECTION • Inspect the brake disc for damage. • 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) ...

  • Page 171: Front Caliper Removal And Disassembly

    15-8 FRONT AND REAR BRAKES FRONT CALIPER REMOVAL AND DISASSEMBLY • Drain brake fluid. (15-4) • Place a rag under the brake hose union bolt to catch spilled brake fluid. • Disconnect the brake hose. • Remove the caliper mounting bolts 1. •...

  • Page 172: Rear Caliper Removal And Disassembly

    FRONT AND REAR BRAKES 15-9 • Remove the dust seals 6 and piston seals 7. REAR CALIPER REMOVAL AND DISASSEMBLY • Remove the rear wheel. (14-6) • Remove the disc cover 1 and caliper protector 2. • Drain brake fluid. (15-4) •...

  • Page 173: Caliper Inspection

    15-10 FRONT AND REAR BRAKES • Wrap the caliper with a rag to prevent brake fluid scatter and piston pop-out. • Apply low-pressure air into the caliper through the hole to remove the piston. WARNING Fingers can get caught between piston and caliper body when removing the piston.

  • Page 174: Caliper Cleaning

     Specification and classification: DOT 4 • Install the springs and boots. • Apply SUZUKI SILICONE GREASE to the caliper axles.  99000-25100: SUZUKI SILICONE GREASE • Install the caliper bracket.

  • Page 175: Rear Caliper Reassembly

     Specification and classification: DOT 4 • Install the springs and boots. • Apply SUZUKI SILICONE GREASE to the caliper axles.  99000-25100: SUZUKI SILICONE GREASE • Install the caliper bracket.

  • Page 176: Master Cylinder

    FRONT AND REAR BRAKES 15-13 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 177: Rear Master Cylinder Removal And Disassembly

    15-14 FRONT AND REAR BRAKES • Remove the master cylinder cap. • Remove the diaphragm. • Remove the dust boot 1. • Remove the snap ring 2 with snap ring pliers. • Remove the washer 3 and piston/cup set 4. ...

  • Page 178: Master Cylinder Inspection

    FRONT AND REAR BRAKES 15-15 MASTER CYLINDER INSPECTION • Inspect the cylinder bore and piston for scuffing, wear and damage. • Inspect the piston rod and spring for damage. MASTER CYLINDER CLEANING • Flush the master cylinder ports with pressurized air. •...

  • Page 179: Rear Master Cylinder Reassembly

    • Apply grease to the contact point between piston and push rod.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Set the brake hose end between the hose stopper, then tighten the brake hose union bolt 1 to the specified torque.

  • Page 180: Brake Lever

    • Apply grease to the brake lever adjuster return spring, pivot bolt and contact point between piston and brake lever.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Tighten the pivot bolt and pivot nut to the specified torque.

  • Page 181: Brake Pedal

    • Remove the washer and master cylinder rod pin 3. • Remove the brake pedal pivot bolt 4. REASSEMBLY • Apply SUZUKI SUPER GREASE to the oil seal and brake pedal pivot bolt.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) •...

  • Page 182: Front Fork And Steering

    FRONT FORK AND STEERING 16-1 FRONT FORK AND STEERING CONTENTS CONSTRUCTION ..................16- 2 FRONT FORK, STEERING ..............16- 2 HANDLEBAR CONTROLS ..............16- 3 REMOVAL ................... 16- 4 DISASSEMBLY ................... 16- 5 INSPECTION ..................16- 9 REASSEMBLY ..................16-11 INSTALLATION ...................

  • Page 183: Construction

    16-2 FRONT FORK AND STEERING CONSTRUCTION FRONT FORK, STEERING 25 N . m (2.5 kgf-m, 18.0 lb-ft) 100 N . m (10.0 kgf-m, 72.5 lb-ft) 23 N . m (2.3 kgf-m, 16.5 lb-ft) 45 N . m 30 N . m (3.0 kgf-m, 21.5 lb-ft) (4.5 kgf-m, 32.5 lb-ft) 35 N .

  • Page 184: Handlebar Controls

    FRONT FORK AND STEERING 16-3 HANDLEBAR CONTROLS Adhesive agent 25 N·m (2.5 kgf-m, 18.0 lb-ft) 6 N·m (0.6 kgf-m, 4.4 lb-ft) Adhesive agent 6 N·m (0.6 kgf-m, 4.4 lb-ft)

  • Page 185: Removal

    16-4 FRONT FORK AND STEERING REMOVAL • Place the motorcycle on a block to lift front wheel off the ground. • Remove the front wheel. (14-3) • Remove the protector 1. • Remove the front number plate band. • Remove the handlebars. (16-18) •...

  • Page 186: Disassembly

    FRONT FORK AND STEERING 16-5 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 187 16-6 FRONT FORK AND STEERING • 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 188 FRONT FORK AND STEERING 16-7 • With the outer tube compressed by hands, remove the special tool. CAUTION Removing the lock-nut 4 and pushing the inner rod thread into the damper rod will damage the inner rod oil seal. Do not remove the lock-nut 4 from the inner rod. •...
  • Page 189 16-8 FRONT FORK AND STEERING 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 190: Inspection

    FRONT FORK AND STEERING 16-9 • 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. • Drain the fork oil from the damper rod assembly by moving the inner rod several strokes.
  • Page 191 16-10 FRONT FORK AND STEERING 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 192: Reassembly

    FRONT FORK AND STEERING 16-11 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 193 • With the damper rod in fully extended position, pour the spec- ified amount of fork oil.  Fork oil quantity (Inside the damper rod): 193 ml (6.52/6.80 US/lmp oz)  99000-99001-SS5: SUZUKI FORK OIL SS-05 (or equivalent fork oil)
  • Page 194 FRONT FORK AND STEERING 16-13 • 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 195 16-14 FRONT FORK AND STEERING • 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 196 FRONT FORK AND STEERING 16-15 • 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 197 • Pour the specified amount of fork oil into the outer tube.  Oil quantity (When standard fork spring is used): 357 ml (12.07/12.57 US/lmp oz)  99000-99001-SS5: SUZUKI FORK OIL SS-05 (or equivaient fork oil) • Raise the outer tube and temporarily tighten the fork cap bolt (sub-tank).

  • Page 198: Installation

    FRONT FORK AND STEERING 16-17 INSTALLATION • Install the front fork with the line T aligned with the upper sur- face of the upper bracket. • Check that the air valve A is positioned at the front. • Tighten the fork lower clamp bolts to the specified torque. ...

  • Page 199: Steering

    16-18 FRONT FORK AND STEERING STEERING REMOVAL HANDLEBARS • Place the motorcycle on a block to lift front wheel off the ground. • Remove the front number plate and protector. (5-2, 16-4) • Remove the clamps. • Remove the clutch lever 1. •...
  • Page 200 FRONT FORK AND STEERING 16-19 STEERING STEM • Remove the front wheel. (14-3) • Remove the front forks. (16-4) • Remove the front fender. • Remove the steering stem head nut. • Remove the steering stem upper bracket. • Remove the steering stem nut with the special tools. ...

  • Page 201: Inspection

    16-20 FRONT FORK AND STEERING INSPECTION STEERING STEM • Inspect the needle bearings for wear. • Inspect the steering stem for distortion. • Inspect the bearing outer races for wear. BEARING REPLACEMENT NOTE: Replace the outer race and bearing as a set. •...

  • Page 202: Installation

    09924-84510: Bearing installer set INSTALLATION STEERING STEM • Apply grease to the bearings.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Fit the steering stem lower bracket, upper bearing and steer- ing stem nut. • Tighten the steering stem nut with the special tools.
  • Page 203 16-22 FRONT FORK AND STEERING HANDLEBARS • Apply adhesive agent to the left handlebar end and inside of the left grip. HANDLE GRIP BOND (commercial available) ” mark on the left grip with the paint mark A on • Align the “ the left handlebar end.
  • Page 204 FRONT FORK AND STEERING 16-23 • Apply grease to the throttle cable and their hole.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Align the “ ” mark on the throttle grip with the hole on the throttle rotor.
  • Page 205 16-24 FRONT FORK AND STEERING Inspect the following items. • Front fork (2-20) • Steering (2-22) • Wire, cable and hose routing (18-12, -13, -17)
  • Page 206 REAR SUSPENSION 17-1 REAR SUSPENSION CONTENTS CONSTRUCTION ..................17- 2 REAR SUSPENSION ................17- 2 REAR SHOCK ABSORBER ..............17- 3 REMOVAL ................... 17- 3 SPRING REPLACEMENT ..............17- 4 INSPECTION ..................17- 5 BEARING REPLACEMENT ..............17- 5 OIL REPLACEMENT ................17- 6 DISASSEMBLY AND INSPECTION ...........

  • Page 207: Construction

    17-2 REAR SUSPENSION CONSTRUCTION REAR SUSPENSION 80 N . m (8.0 kgf-m, 58.0 lb-ft) 55 N . m (5.5 kgf-m, 40.0 lb-ft) 80 N . m (8.0 kgf-m, 58.0 lb-ft) 80 N . m 55 N . m (8.0 kgf-m, (5.5 kgf-m, 58.0 lb-ft) 40.0 lb-ft)

  • Page 208: Rear Shock Absorber

    REAR SUSPENSION 17-3 REAR SHOCK ABSORBER REMOVAL • Place a block under chassis tube. • Remove the seat. (5-3) • Loosen the air cleaner clamp screw. • Remove the right frame cover. (5-2) (For E-19, 000) (For E-19, 000) • Remove the silencer and rear frame assembly. •...

  • Page 209: Spring Replacement

    17-4 REAR SUSPENSION • Remove the rear shock absorber lower mounting bolt and nut. • Remove the rear shock absorber. NOTE: If necessary, move the swingarm up or down to facilitate this mounting bolt/nut removal. SPRING REPLACEMENT • Loosen the lock-nut 1 with the special tool and turn it fully to the end of the thread.

  • Page 210: Inspection

    REAR SUSPENSION 17-5 INSPECTION • Inspect the rear shock absorber for oil leakage. • Inspect the damper rod for bends and smooth movement. • Inspect the bump rubber for deterioration and damage. • Inspect the damper rod hidden by the bump rubber by moving the bump rubber.

  • Page 211: Oil Replacement

    • Apply grease to the dust seals and spacers. • Install the spacers A and B. A for Right side B for Left side  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) OIL REPLACEMENT TOOLS AND EQUIPMENT • Following tools and equipment are required to perform oil replacement.
  • Page 212 REAR SUSPENSION 17-7 OIL REPLACEMENT PROCEDURE • Remove the rear shock absorber unit from the frame (17-4), clean and dry it. • Remove the spring from the rear shock absorber unit. (17-4) 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 213 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 (or equivalent rear suspension oil) ...

  • Page 214: Disassembly And Inspection

    REAR SUSPENSION 17-9 • Reinstall the compression adjuster assembly 1.  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). • Tighten the gas valve cap. •...
  • Page 215 17-10 REAR SUSPENSION • Vise the rear shock absorber unit in inverted position. • Depress the bump rubber fully to protect the damper rod. • Evenly hammer the stopper 1 with a screwdriver or equiva- lent and remove it from the rear shock absorber body. •...

  • Page 216: Reassembly

    • Fit the stopper to the shock absorber body. • Fill the specified rear suspension oil in the rear shock absorber. (17-8) 99000-99001-S25: SUZUKI REAR SUSPENSION OIL SS-25 (or equivalent rear suspension oil)  Oil capacity: Approx. 380 ml (12.84/13.38 US/Imp oz) •...

  • Page 217: Disposal

    17-12 REAR SUSPENSION DISPOSAL High pressure nitrogen gas is sealed in the rear shock absorber unit. Be sure to release gas before disposing the rear shock absorber unit. • Remove the valve cap. • Press the valve with a screwdriver. WARNING Releasing high pressure gas from the rear shock absorber unit can be hazardous.

  • Page 218: Swingarm

    REAR SUSPENSION 17-13 SWINGARM REMOVAL • Place the motorcycle on a block to lift rear wheel off the ground. • Remove the rear wheel. (14-6) • Remove the chain guide. • Remove the rear brake hose guide. • Remove the rear brake caliper from the swingarm. •...

  • Page 219: Inspection

    17-14 REAR SUSPENSION • Remove the chain buffer. • Remove the plates. • Remove the following parts from the swingarm. Spacer 1 Oil seal 2 Washer 3 Thrust bearing 4 Dust seal 5 Spacer 6 INSPECTION PIVOT SHAFT • Measure the pivot shaft runout with the dial gauge and V-blocks.

  • Page 220: Bearing Replacement

    REAR SUSPENSION 17-15 SWINGARM • Inspect the swingarm for cracks and damage. BEARING, SPACER, DUST SEAL, OIL SEAL • Inspect the bearings, spacers, dust seals and oil seals for damage. • Insert the spacer into the bearings and inspect them for play and smooth movement.

  • Page 221: Installation

    17-16 REAR SUSPENSION • Apply grease to the bearings.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) INSTALLATION • Reassemble the following parts into the swingarm. 1 Oil seal 5 Washer 2 Spacer 6 Dust seal 3 Washer 7 Spacer 4 Thrust bearing •...

  • Page 222: Rear Suspension Linkage

    REAR SUSPENSION 17-17 REAR SUSPENSION LINKAGE REMOVAL • Place a block under the chassis tubes. • Remove the lower drive chain control roller 1. • Remove the rear cushion rod bolt and nut. • Remove the cushion lever bolt and nut. •...

  • Page 223: Inspection

    17-18 REAR SUSPENSION INSPECTION • Inspect the cushion rod and cushion lever for damage. • Inspect the dust seals and spacers for damage. • Insert the spacers into the bearings and inspect them for excessive play and smooth movement. BEARING REPLACEMENT •...

  • Page 224: Reassembly

    When installing the needle roller bearing cages, the stamped mark on the bearing must face outside. • Apply grease to the needle roller bearings and install them.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Press fit the needle roller bearing cages with the special tool and a suitable size socket wrench.
  • Page 225 17-20 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: 55 N·m (5.5 kgf-m, 40.0 lb-ft) B: 55 N·m (5.5 kgf-m, 40.0 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 226 REAR SUSPENSION 17-21 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 227 – MEMO –...

  • Page 228: Servicing Information

    SERVICING INFORMATION 18-1 SERVICING INFORMATION CONTENTS SERVICE DATA ..................18- 2 CYLINDER + PISTON + PISTON RING..........18- 2 CONROD + CRANKSHAFT ..............18- 2 CLUTCH ....................18- 2 RADIATOR ..................18- 3 TRANSMISSION .................. 18- 3 DRIVE CHAIN..................18- 3 CARBURETOR ..................

  • Page 229: Service Data

    18-2 SERVICING INFORMATION SERVICE DATA CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT Piston to cylinder clearance 0.030 – 0.040 0.120 (0.0012 – 0.0016) (0.0047) Cylinder bore 54.000 – 54.015 Nicks or (2.1260 – 2.1266) Scratches Measure 20 (0.79) from the top surface.

  • Page 230: Radiator

    SERVICING INFORMATION 18-3 RADIATOR ITEM STANDARD LIMIT Radiator cap valve release 95 – 125 kPa — pressure (0.95 – 1.25 kgf/cm , 13.5 – 17.8 psi) TRANSMISSION Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3.368 (64/19) —...

  • Page 231: Electrical

    18-4 SERVICING INFORMATION ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Ignition timing 5° B.T.D.C. at 1 000 r/min. Spark plug Type NGK: R6918B-8 0.55 – 0.65 (0.022 – 0.026) Spark performance Over 8 (0.3) at 1 atm. Pick-up coil resistance 72 –...

  • Page 232: Suspension

    SERVICING INFORMATION 18-5 ITEM STANDARD LIMIT 1.60 × 21 Wheel rim size Front 1.85 × 19 Rear Wheel axle runout 0.25 Front — (0.010) 0.25 Rear — (0.010) SUSPENSION Unit: mm (in) ITEM STANDARD LIMIT NOTE Front fork stroke — (12.2) Front fork inner tube 47 mm...

  • Page 233: Tire

    750 ml Change (0.8/0.7 US/Imp qt) 800 ml Overhaul (0.8/0.7 US/Imp qt) Front fork oil type SUZUKI fork oil SS-05 or equivalent fork oil Front fork oil capacity 357 ml Outer tube oil (each leg) (12.07/12.57 US/Imp oz) quantity 193 ml Damper rod (6.52/6.80 US/lmp oz)

  • Page 234: Tightening Torque

    SERVICING INFORMATION 18-7 TIGHTENING TORQUE PART N·m kgf-m lb-ft Cylinder head nut 18.0 Magneto rotor nut 25.5 Cylinder nut 18.0 Crankcase bolt Clutch sleeve hub nut 50.5 Primary drive gear bolt 50.5 Spark plug 17.5 1.75 12.5 Transmission oil drain plug 14.5 Transmission oil level bolt 0.55...
  • Page 235 18-8 SERVICING INFORMATION PART N·m kgf-m lb-ft Handlebar holder set nut 11.0 Seat rail nut (upper) 16.5 Seat rail bolt (lower) 16.5 Brake lever pivot bolt Brake lever pivot nut For other bolts and nuts not listed in the table, refer to this chart. Conventional or “4”...

  • Page 236: Special Tools

    SERVICING INFORMATION 18-9 SPECIAL TOOLS 09900-20101 09900-00410 09900-06107 09900-06108 09900-09003 Vernier calipers Hexagon wrench set Snap ring pliers Snap ring pliers Impact driver set (150 mm) 09900-20203 09900-20205 09900-20605 09900-20607 Micrometer Micrometer 09900-20508 Dial gauge Dial gauge (50 – 75 mm) (0 –...
  • Page 237 18-10 SERVICING INFORMATION 09925-18011 09921-20200 09921-20240 09924-84510 09924-84521 Steering bearing Bearing remover Bearing remover set Bearing installer set Bearing installer set installer 09930-10121 09930-30104 09930-30113 Spark pulg wrench 09930-11960 Rotor remover slide Flywheel rotor 09930-40113 Torx wernch (T20) shaft remover Rotor holder 09940-14911 09940-14960...

  • Page 238: Wiring Diagram

    SERVICING INFORMATION 18-11 WIRING DIAGRAM IGNITION COIL CARBURETOR CDI UNIT ENGINE SOLENOID STOP SWITCH : Pickup THROTTLE coil POSITION SENSOR MAGNETO WIRE COLOR Black Blue Green White Yellow B/Bl: Black with Blue tracer B/Br: Black with Brown tracer B/G: Black with Green tracer B/O: Black with Orange tracer B/R:...

  • Page 239: Wire, Cable And Hose Routing

    18-12 SERVICING INFORMATION WIRE, CABLE AND HOSE ROUTING Clamp Pass through the clutch cable under the radiator breather hose. Clutch cable Throttle cable Pass through the clutch cable between the engine mounting plates. Throttle cable Clutch cable Clutch cable Throttle cable...
  • Page 240 SERVICING INFORMATION 18-13 Clamp Engine stop switch lead wire FRONT Ignition coil coupler Clamp Wiring harness Engine stop switch lead wire Frame Clamp CDI unit Wiring harness Engine stop switch lead wire Throttle cable Clamp Wiring harness Engine stop switch lead wire Clamp Carburetor solenoid lead wire Throttle position sensor lead wire...
  • Page 241 18-14 SERVICING INFORMATION...
  • Page 242 SERVICING INFORMATION 18-15 NOTE: Face each clamp end to the downward. Clamp Fuel tank cushion rubber Fuel tank Clamp cushion rubber Clamp SECT AA Protector 10 mm (0.4 in)
  • Page 243 18-16 SERVICING INFORMATION Quick adjuster Turn to tighten Turn to tighten the clutch cable tension. the clutch cable tension. When the movement is felt heavier, Turn to loosen Turn to loosen clean this and apply grease. the clutch cable tension. the clutch cable tension.
  • Page 244 SERVICING INFORMATION 18-17 Front brake master cylinder Washer Front brake hose Hose guide Set the brake hose end between the hose stopper, then tighten the brake hose union bolt to the specified torque. Front brake hose Clamp Clamp the upper difference portion in brake hose diameter.
  • Page 245 18-18 SERVICING INFORMATION...
  • Page 246 SERVICING INFORMATION 18-19...

  • Page 247: Specifications

    18-20 SERVICING INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ............2 145 mm (84.4 in) Overall width ............830 mm (32.7 in) Overall height ............1 275 mm (50.2 in) Wheelbase ............1 450 mm (57.1 in) Ground clearance ..........350 mm (13.8 in) Seat height............

  • Page 248: Chassis

    SERVICING INFORMATION 18-21 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, hydraulically operated Rear brake............

  • Page 249: Spare Parts List

    18-22 SERVICING INFORMATION SPARE PARTS LIST ITEM PART NAME PART NUMBER Q’TY PARTS SET, SPARE 19900-36F70 O-RING, CYLINDER HEAD No. 1 11147-27C11 O-RING, CYLINDER HEAD No. 2 11148-27C11 GASKET, CYL COVER, No. 1 11233-27C34 GASKET, CYL COVER, No. 2 11238-36E01 GASKET, CYLINDER 11241-36F00 GASKET, CRANKCASE...

  • Page 250: Setting Data

    SERVICING INFORMATION 18-23 SETTING DATA DATE RACE/COURSE TEMP./HUMIDITY WHETHER COURSE COUDITION MAIN JET JET NEEDLE PILOT JET AIR SCREW FLOAT LEVEL SPARK PLUG OIL LEVEL COMP. ADJ. POSITION RE-BOUND ADJ. POSITION SPRING SPRING SPRING SET LENGTH COMP. ADJ. POSITION LOW COMP.
  • Page 251 – MEMO –...
  • Page 252 Failure to follow these safety precautions may increase your risk of injury: ! Wear a helmet, eye protection, and bright protective clothing. ! Don’t ride after consuming alcohol or other drugs. ! This owner’s service manual contains important safety information. Please read it carefully. Printed in Japan 300 TAKATSUKA, HAMAMATSU, JAPAN...

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