Suzuki AP 50 Manuals

Manuals and User Guides for Suzuki AP 50. We have 1 Suzuki AP 50 manual available for free PDF download: Service Manual

Suzuki AP 50 Service Manual (189 pages)

Brand: Suzuki | Category: Scooter | Size: 23.25 MB

Group Index
2
Component Parts and Work to be Done
3
Symbol
4
General Information
5
Warning/Caution/Note
6
General Precautions
6
Serial Number Location
8
Fuel
8
Engine Oil
8
Final Gear Oil
9
Brake Fluid
9
Front Fork Oil
9
Break-In Procedures
9
Information Labels
10
Specifications
11
Dimensions and Dry Mass
11
Chassis
11
Country or Area
12
Periodic Maintenance
13
Periodic Maintenance Schedule
14
Periodic Maintenance Chart
14
Lubrication Points
15
Maintenance and Tune-Up Procedure
16
Battery
16
Hydrometer
16
Air Cleaner
17
Cylinder Head and Cylinder
18
Spark Plug
18
Spark Plug Gap
18
Carburetor
19
Throttle Cable Play
19
Engine Idle R/Min
19
Fuel Line
19
Brakes
20
Front Brake Fluid Level
20
Front Brake Pads
20
Bleeding Air from the Brake Fluid Circuit
21
Rear
22
Brake Shoe Wear
22
Steering
22
Front Fork
22
Rear Suspension
23
Tires
23
Tire Pressure
23
Tire Tread Condition
23
Cylinder Head Nuts and Exhaust Pipe Bolt and Nut
24
Chassis Bolts and Nuts
24
Automatic Clutch Inspection
26
Initial Engagement Inspection
26
Clutch Lock-Up Inspection
26
Engine
27
Engine Removal
29
Engine Remounting
31
Engine Disassembly
32
Engine Components Inspection and Servicing
39
Bearings
39
Oil Seals
39
Crankshaft
42
Crankshaft Runout
42
Condition of Big End Bearing
42
Conrod Small End I.D.
42
Clutch and Movable Driven
43
Disassembly
43
Clutch Shoe
45
Driven Face Spring
45
Driven Face Pin and Oil Seal
46
Driven Face
46
Reassembly
46
Movable Drive
47
Roller and Sliding Surface
47
Drive Belt
48
Cylinder Head
48
Cylinder
48
Cylinder Gauge Set
48
Piston
49
Cylinder to Piston Clearance
49
De-Carboning
49
Piston Pin Bore
50
Piston Pin O.D.
50
Piston Rings
50
Reed Valve
51
Engine Reassembly
52
Bushings
53
Rear Axle Shaft
56
Transmission
58
Starter Pinion and Starter Gear
60
Kick Starter
63
Fuel and Lubrication System
66
Fuel Valve
67
Fuel Tank and Oil Tank
68
Fuel Tank and Oil Tank Cushions
69
Needle Valve Inspection
73
Float Height Adjustment
73
Oil Pump
75
Air Bleeding
75
Checking Oil Pump
75
Leg Shield and Frame Cover
77
Leg Shield Removal
78
Frame Cover Removal
79
Front Wheel
80
Speedometer Gearbox Dust Seal
81
Wheel Bearings
81
Wheel
82
Tire
82
Front Axle
82
Wheel Bearing
82
Brake Disc
83
Speedometer Gearbox
83
Front Brake
84
Brake Pad Replacement
85
Brake Fluid Replacement
85
Caliper Removal and Disassembly
86
Caliper Inspection
87
Caliper Reassembly and Remounting
87
Caliper
87
Disc Inspection
88
Master Cylinder Removal and Disassembly
88
Master Cylinder Reassembly and Remounting
90
Fork Spring
93
Inner and Outer Tubes
93
Damper Rod Ring
93
Damper Rod Bolt
94
Oil Seal
94
Fork Oil
94
Stopper Ring
95
Handlebar Cover
96
Steering Stem
98
Inner Races
100
Steel Ball
100
Steering Stem Nut
101
Rear Wheel, Brake and Shock Absorber
102
Brake Drum
103
Rear Shock Absorber
103
Brake Shoe
103
Electrical System
105
Cautions in Servicing
106
Connector
106
Coupler
106
Clamp
106
Connecting Battery
107
Wiring Procedure
107
Using Pocket Tester
107
Location of Electrical Components
108
Charging and Lighting System
109
Battery Runs down Quickly
109
Charging Output Check
110
No-Load Performance
111
Stator Coils
111
Regulator/Rectifier
111
Starter System Description
112
Starter Motor will Not Run
112
Starter Motor Inspection
114
Carbon Brushes
114
Commutator
114
Armature Coil
114
Starter Relay Inspection
115
Pocket Tester
115
Ignition System
116
No Spark at Plug
116
CDI Unit and Ignition Coil Inspection
117
Checking with Electro Tester
117
Checking with Suzuki Pocket Tester
117
Magneto Exciting Coil
117
Speedometer
118
Fuel Meter and Gauge
119
Fuel Meter Inspection
119
Fuel Gauge Inspection
119
Oil Level Indicator Switch
120
Thermoelement
120
Switches
121
Ignition Switch
121
Horn Button
121
Lighting Switch
121
Initial Charging
122
Filling Electrolyte
122
Charging Time
122
Confirmation for Date of Manufacture
122
Recharging Operation Based on S.G. Reading
123
Service Life
124
Servicing Information
128
Wiring Diagram
135
Wire, Cable and Hose Routing
139
Wire Routing
139
Cable Routing
141
Carburetor and Fuel Hose Routing
142
Special Tools
147
Tightening Torque
149
Tightening Torque Chart
150
Service Data
151
Ap50T
155

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Suzuki AP 50 Service Manual (189 pages)

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